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Bray FLOW-TEK 19 Series Installation, Operation And Maintenance Manual Download Page 4

FLOW-TEK SERIES 19 SEGMENTED BALL VALVE

Installation, Operation, and Maintenance Manual

4 of 39

© 2021 BRAY INTERNATIONAL, INC. ALL RIGHTS RESERVED. BRAY.COM   The Information 

contained herein shall not be copied, transferred, conveyed, or displayed in any manner that would 

violate its proprietary nature without the express written permission of Bray International, Inc.

2.0  

INTRODUCTION

2.1

Information provided in this manual is for 

S19 

segmented ball 

valves only. Specific instructions for non-standard materials of 
construction, temperature range, etc. should be referred to the 
factory.

2.2

This manual covers 

S19 

valves in the following range:

 

> NPS 1 to 16 | DN 25 to 400

 

> ASME Class 150, 300, 600 | PN 10, 16, 25, 40

 

> Body Style: Flanged, Flangeless

2.3

Additional product information (such as application data, 
engineering specifications, actuator selection, etc.) is available 
from your local Bray distributor or sales representative, or online 
at 

BRAY.COM

2.4

For complete details on the latest product certifications, visit 

BRAY.COM/Certifications

.

2.5

The 

S19 

segmented ball valve is designed per ASME B16.34.

Summary of Contents for FLOW-TEK 19 Series

Page 1: ...FLOW TEK SERIES 19 SEGMENTED BALL VALVE Installation Operation and Maintenance Manual BRAY COM THE HIGH PERFORMANCE COMPANY ...

Page 2: ...TION 5 4 0 VALVE IDENTIFICATION 9 5 0 GENERAL INFORMATION 10 6 0 HANDLING REQUIREMENTS 12 7 0 STORAGE 14 8 0 INSTALLATION 16 9 0 OPERATION 19 10 0 PREVENTATIVE MAINTENANCE 20 11 0 ACTUATOR REMOVAL AND REMOUNTING 21 12 0 REMOVING VALVE FROM PIPELINE 22 13 0 SEAT REPLACEMENT S19 ASME 150 300 PN 10 16 25 40 23 14 0 DISASSEMBLY AND INSPECTION S19 ASME 150 300 PN 10 16 25 40 24 15 0 REASSEMBLY S19 ASME...

Page 3: ...RNING CAUTION and NOTICE are used in this document to prevent unwanted consequences Standard symbols and classifications are DANGER Indicates an immediate hazardous situation which if not avoided will result in death or serious injury and or property damage WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury and or property damage CAUTIO...

Page 4: ...ll valves only Specific instructions for non standard materials of construction temperature range etc should be referred to the factory 2 2 This manual covers S19 valves in the following range NPS 1 to 16 DN 25 to 400 ASME Class 150 300 600 PN 10 16 25 40 Body Style Flanged Flangeless 2 3 Additional product information such as application data engineering specifications actuator selection etc is a...

Page 5: ... shall not be copied transferred conveyed or displayed in any manner that would violate its proprietary nature without the express written permission of Bray International Inc 23 24 14 15 16 13 12 11 10 6 8 22 1 30 29 28 27 7 9 17 18 19 20 21 3 4 5 26 2 25 Resilient Seat Metal Seat 3 0 PARTS IDENTIFICATION 3 1 Parts Callout S19 ASME 150 300 PN 10 16 25 40 INTERCHANGEABLE SEAT DESIGN ...

Page 6: ...PTION RECOMMENDED SPARE PARTS 1 Body 2 Seat 3 Seat Spring 4 Seat O Ring 5 Segment 6 Stem Bearing 7 End Post Bearing 8 Stem 9 End Post 10 Thrust Washer 11 Stem Seal Kit 12 Gland Ring 13 Gland Retainer 14 Gland Stud 15 Gland Lock Washer 16 Gland Nut 17 Post Cover Gasket 18 Post Cover 19 Post Cover Washer 20 Post Cover Stud 21 Post Cover Nut 22 Mounting Bracket 23 Bracket Washer 24 Bracket Screw 25 S...

Page 7: ... contained herein shall not be copied transferred conveyed or displayed in any manner that would violate its proprietary nature without the express written permission of Bray International Inc 22 21 18 8 6 7 9 10 11 27 14 12 13 5 2 3 4 29 28 26 31 33 30 32 19 15 16 17 23 24 25 20 1 Resilient Seat Metal Seat 3 3 Parts Callout S19 ASME 600 INTERCHANGEABLE SEAT DESIGN ...

Page 8: ... Body 2 Seat 3 Seat Spring 4 Seat O Ring 5 Segment 6 Stem 7 Stem Bearing 8 Split Ring 9 Thrust Washer 10 Packing Spacer 11 Stem Seal Kit 12 Gland Ring 13 Retaining Ring 14 Gland Retainer 15 Gland Stud 16 Gland Lock Washer 17 Gland Nut 18 End Post 19 End Post Bearing 20 End Post Thrust Washer 21 Post Cover Gasket 22 Post Cover 23 Post Cover Stud 24 Post Cover Lock Washer 25 Post Cover Nut 26 Mounti...

Page 9: ...d conveyed or displayed in any manner that would violate its proprietary nature without the express written permission of Bray International Inc 4 0 VALVE IDENTIFICATION 4 1 Identification Tag All valves actuators or control products are provided with a permanently affixed identification tag meeting the requirements of applicable standards and certifications for the product As each product is uniq...

Page 10: ...tended service The identification tags describe the maximum allowable service conditions for this product Be sure that the installation is protected by appropriate pressure control and safety devices to ensure that acceptable limits are not exceeded 5 2 Operation Operation of the valve is done by turning the stem a quarter turn 90 degree turn Clockwise to close counter clockwise to open CAUTION Va...

Page 11: ... include appropriate education training experience and knowledge of relevant standards specifications operating conditions and accident prevention 5 6 Spare Parts Use only Bray original spare parts Recommended spare parts are identified in the Parts Identification drawing and list for each product model Bray cannot accept responsibility for any damages that occur from using spare parts or fastenin...

Page 12: ... use straps through valve body Take care to position lifting straps to avoid damage to the tubing and mounted accessories 6 2 Unpacked Valves Lifting and handling of valves should be carried out by using appropriate means and observing the carrying limits Handling must be carried out on pallets protecting all machined surfaces to avoid any damage With large bore valves rigging the load must be car...

Page 13: ...erials received Lists describing the valve and accessories are included in each shipping container and general assembly drawing as applicable WARNING Never lift the valve or valve package by the actuator positioner limit switch or their piping When lifting a valve be aware that the center of gravity may be above the lifting point Therefore support must be given to prevent the valve from rotating F...

Page 14: ...ct within a relatively short amount of time typically one to three months During short term storage the following is required 7 1 1 The preferred storage location is a closed clean and dry environment Do not expose the product to temperature extremes 7 1 2 Valve should be stored in closed position 7 1 3 End protectors shall remain on valve ends to prevent the entrance of dirt debris or insects wil...

Page 15: ...to prevent the entrance of dirt debris or insects wildlife 7 2 4 Product shall remain in the original shipping container with the original packaging materials CAUTION Do not stack the valves on top of each other 7 2 5 Manually actuated valves may be stored in the vertical or horizontal position For air or hydraulically actuated valves the preferred orientation is with the valve and cylinder in the...

Page 16: ...andle or actuator has been removed do not rotate segment beyond fully open or closed position as this could cause damage to sealing surfaces Provide proper overhead clearance to allow for disassembly of the actuator from the valve body Refer to the appropriate General Assembly Drawing for proper clearances Provide necessary support for accessories when center of gravity for complete assembly is fu...

Page 17: ...rizontal or vertical orientation When installed with the bore in the horizontal orientation it is recommended to also place the stem in the horizontal position resulting in the segment opening towards the top of the body cavity 8 4 Gaskets Gaskets should conform to the requirements of API 601 for ASME B16 5 class flanges Spiral wound gaskets such as Flexitallic CG or CGl series conforming to ASME ...

Page 18: ...ons must be completely tight CAUTION On valves equipped with air filters the air filter must point down to perform properly 8 8 Pre Commissioning Check Before commissioning check the valve by following these steps 8 8 1 Check for full stroke by varying the instrument signal settings appropriately Observe the segment position indicator located on the actuator or the positioner The segment should ch...

Page 19: ...urning the stem a quarter turn 90 degree turn The stem is turned clockwise to close counter clockwise to open 9 2 Indication The valve open and closed position are indicated by the position of indentation on the stem Valve OPEN position Flats of Double D stem are parallel to pipeline Valve CLOSED position Flats of Double D stem are perpedicular to pipeline CAUTION Valves with actuators should be i...

Page 20: ...tion 10 5 Check packing gland retainer bolting for proper tightness If there is a persistent leak that cannot be stopped by tightening of the gland nuts replace the packing Refer to Disassembly Assembly section in this document CAUTION Do not over tighten packing This can cause excessive packing wear and high stem friction that may impede stem movement Reference Tables in Appendix A for recommende...

Page 21: ...11 1 2 Neutralize all energy sources electrical pressure and mechanical 11 1 3 Support the actuator assembly before disconnecting it from the body assembly 11 1 4 Unbolt the actuator assembly from valve mounting bracket 11 1 5 Lift actuator assembly off stem 11 2 Remounting Actuator 11 2 1 Before mounting an actuator on the valve body verify that the segment rotation matches the actuator rotation ...

Page 22: ... atmospheric pressure drain all process fluids and decontaminate the valve if caustic or hazardous materials are present Failure to do so can cause serious injury Make sure the valve is in closed position 12 2 Neutralize all energy electrical pressure and mechanical sources 12 3 Attach a hoist or some means to support the valve 12 4 Remove line bolting CAUTION Do not attempt to pry line flanges ap...

Page 23: ...dges using a fine abrasive paper and clean the flow port carefully prior to installing the seat 13 2 2 Place the seat o ring onto the seat 13 2 3 Lubricate the flow port seat seat o ring and the seat spring s with a volatile light lubricant NOTE Ensure the lubricant is compatible with the process medium Prior to using any lubricant review the product safety data sheet for compatibility and safety ...

Page 24: ...post cover and the body to remove the post cover and gasket 14 1 8 Using a punch and mallet drive the stem pin and end post pin into the center of the stem and end post until the outward end of the pin clears the segment Be careful not to damage the stem or end post NOTE The pins can be removed from the stem and end post by driving them out of the through holes with a mallet and punch once the seg...

Page 25: ...prietary nature without the express written permission of Bray International Inc 14 2 Inspection of Removed Parts 14 2 1 Clean the removed parts NOTICE Cleaning should be done with acetone or equivalent product 14 2 2 Visually inspect the stem and bearings for abnormal wear or damage 14 2 3 Visually inspect the sealing surface of the segment and seat for abnormal wear or damage 14 2 4 If necessary...

Page 26: ...ce to make sure it is smooth and free of scoring and scratches CAUTION Damaged or dirty seal surfaces can cause excessive seat wear and high torque requirements Damaged segment should be replaced 15 2 2 Insert the segment into the body through the downstream bore splined shaft hole first towards the upstream seat pocket Once the segment is fully in the body cavity rotate the segment placing the sp...

Page 27: ...nsert stem seal kit over the drive end of the stem into stuffing box bore NOTICE When packing set with PTFE rings carbon fiber ring is used carbon fiber packing ring shall be installed at last Always use new packing whenever rebuilding the packing box CAUTION When V ring packing is used it is imperative to avoid damage to the feather edge of the V ring as it is the sealing edge 15 3 7 Install the ...

Page 28: ...t aligning the post segment pin holes 15 4 3 Place the gasket in groove followed by post cover stud washer and nut NOTICE Post cover stud nut shall be torqued as per Table 2 15 4 4 Drive the stem pin and end post pin into the stem and end post until the outward end of the pin becomes flush with the segment Be careful not to damage the stem or end post NOTICE Tools may be necessary to insert the pi...

Page 29: ... fine abrasive paper and clean the flow port carefully prior to installing the seat 16 2 2 Place the seat o ring onto the seat 16 2 3 Lubricate the flow port seat seat o ring and the seat spring s with a volatile light lubricant NOTE Ensure the lubricant is compatible with the process medium Prior to using any lubricant review the product safety data sheet for compatibility and safety protocols 16...

Page 30: ...cover and the body to remove the post cover gasket and end post thrust washer 17 1 8 Using a punch and mallet drive the stem pin into the center of the stem until the outward end of the pin clears the segment Be careful not to damage the stem NOTE The pin can be removed from the stem by driving it out of the through holes with a mallet and punch once the segment has been removed 17 1 9 Remove the ...

Page 31: ...prietary nature without the express written permission of Bray International Inc 17 2 Inspection of Removed Parts 17 2 1 Clean the removed parts NOTICE Cleaning should be done with acetone or equivalent product 17 2 2 Visually inspect the stem and bearings for abnormal wear or damage 17 2 3 Visually inspect the sealing surface of the segment and seat for abnormal wear or damage 17 2 4 If necessary...

Page 32: ...t into the body through the downstream bore splined shaft hole first towards the upstream seat pocket Once the segment is fully in the body cavity rotate the segment placing the splined segment hole in alignment with the packing box 18 2 3 Hold the segment inside the body so that it does not remain unsupported Larger sizes may require overhead lift with slings CAUTION Be extremely careful not to g...

Page 33: ...ing whenever rebuilding the packing box CAUTION When V packings are used it is imperative to avoid damage to the feather edge of the V Ring as it is the sealing edge 18 4 4 Install the gland ring retaining ring split ring gland retainer studs lock washers and nuts NOTE Only tighten the gland nuts hand tight during assembly The gland nuts will receive final tightening to specified torque values at ...

Page 34: ... 5 1 Insert end post into body 18 5 2 Insert bearing onto end post NOTICE Care shall be taken to ensure PTFE lined fabric on bearing is not damaged during assembly 18 5 3 Place thrust washer on end post NOTICE Small quantity of compatible grease adhesive may be used to place thrust washer considering thickness 18 5 4 Place the gasket in groove Install post cover using studs washers and nuts NOTICE...

Page 35: ...gasket leak Loose nuts Retorque nuts Gasket damage Replace gasket Damage corrosion in sealing area Clean or replace bottom plate and or body based on severity of damage Through bore leakage Segment not in fully closed position Adjust close limit travel stops in actuator or check for backlash in actuator drive Segment and seat misaligned Loosen the gland packing and center the segment by cycling va...

Page 36: ...e returned require a Return Merchandise Authorization RMA Contact a Bray representative for instructions and RMA forms to be completed prior to return of any product 0 2 The following information must be provided when submitting RMA Serial number Part number Month and year of manufacture Actuator specifics Application Media Operating temperature Operating pressure Total estimated cycles since last...

Page 37: ... S19 ASME 150 300 PN 10 16 25 40 N m Valve Size Nut size Estimated Torque Maximum Torque DN N m N m 25 5 16 UNC 6 20 40 5 16 UNC 6 20 50 5 16 UNC 6 20 80 5 16 UNC 7 20 100 5 16 UNC 7 20 150 5 16 UNC 10 20 200 3 8 UNC 10 24 250 3 8 UNC 10 24 300 3 8 UNC 11 24 400 M12 27 55 21 0 APPENDIX A TABLES Table 2 Post Cover Torque S19 ASME 150 300 PN 10 16 25 40 lbf in Valve Size Nut size Estimated Torque Ma...

Page 38: ... 10 M10 239 275 12 M12 372 487 16 M16 753 1213 Table 4 Post Cover Torque S19 ASME 600 N m Valve Size Nut size Estimated Torque Maximum Torque DN N m N m 25 M08 6 16 40 M08 6 16 50 M08 7 16 80 M08 10 16 100 M08 10 16 150 M10 19 31 200 M10 19 31 250 M10 27 31 300 M12 42 55 400 M16 85 137 Table 3 Gland Nut Torque S19 ASME 600 lbf in Valve Size Nut size Estimated Torque Maximum Torque NPS lbf in lbf i...

Page 39: ...PANY All statements technical information and recommendations in this bulletin are for general use only Consult Bray representatives or factory for the specific requirements and material selection for your intended application The right to change or modify product design or product without prior notice is reserved Patents issued and applied for worldwide Bray is a registered trademark of Bray Inte...

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