Bray 5000_6000 Series - Manual (Page 2)

Installation and Maintenance Manual
Series 5000 and 6000 Ball Valves
Date: August 2011 / Page 2 of 6
®
A Subsidiary of BRAY INTERNATIONAL, Inc.
FLOW-TEK, Inc. Tel: 832.912.2300 © 2011 Flow-Tek, Inc.
8323 N. Eldridge Pkwy #100 Fax: 832.912.2301
Houston, Texas 77041 www.flow-tek.com
end being tightened. Tightening by using the valve
body, handle or the opposite end cap can seriously
damage the valve; Use a wrench on both the second
end cap and pipe to avoid applying torque to the
body through the bolting.
3. In some applications, threaded end valves may be
back-welded on site. Use caution. Do not overheat the
valve body. Confirm that the end cap bolt holes are
aligned with the body screw holes on both ends and
that the end caps are parallel and correctly spaced
to fit the valve body before re-assembly or back
welding. Make up both of the threaded connections
normally and then remove the body assembly as
described below for weld-end connections before
back welding the threaded connection.
4. Do not use the body screws to pull the pipe ends
together to correct misalignment.
INSTALLATION OF WELD-END VALVES
Insure that weld procedures are implemented that are
compatible with the materials used.
1. Tack weld the assembled valve to the pipe at four
points on both end caps.
2. With the valve in open position, (the valve is in the
open position when the handle is parallel to the axis
of the valve and pipe), loosen all body bolts, take
the body out.
3. Turn the handle in the half open position. Remove the
seats and body gaskets.
4. Turn handle in closed position and remove ball.
5. Place all removed parts in a clean and secure place.
6. Replace the body and all bolts and tighten them slightly.
This operation is very important, so that the body and
end caps remain perfectly parallel, thus preventing any
leakage at the body joint after welding.
7. Finish welding both end caps onto the pipe. Use
temperature indicating crayons to insure that the
body temperature doesn’t exceed 200°F in the area
of the neck or component/seal damage may occur.
8. When cool, remove the body, clean the end caps,
and reassemble per the instructions given below.
9. Place the bodies between the two end connections;
then replace all bolts and cross tighten.
10. (See table 1. Tightening torques for end cap screws).
4. DISASSEMBLY & CLEANING PROCEDURES:
CAUTION: Line must be depressurized before disassembly.
Valve should be cycled after draining the system to relieve
any pressure trapped in the valve body cavity. Ball valves
can trap pressurized media when closed. Flush line with
the valve 1/2 open to remove hazardous media. If the
valve has been used to control hazardous media, it must
be decontaminated before disassembly.
WARNING: DO NOT attempt to remove packing
components or any other valve parts while line is under
pressure!
CAUTION: Properly support the valve before removing
or loosening any body bolts. The larger sizes are heavy
and may cause injury if allowed to swing or fall freely.
Remove the actuation air and power connections and
confirm that there is no stored energy in the actuation such
as compressed springs or trapped air before beginning.
Stored energy devices can cause serious injury if the
energy is released without warning.
DISASSEMBLY FOR STEM AND SEAL SERVICE:
1. It is not necessary to remove the flanges from the
pipeline. Removing the actuation and controls may
make service easier.
2. Remove one of the upper body bolts and loosen the
remaining bolts. The center body section containing the
ball and seals will swing out for service, leaving the end
caps in place on the pipe ends. See illustration below.
3. To completely remove the valve from the pipeline,
remove the remaining upper body bolt and the body
will lift free. Gently support the body in a vise to
complete the remainder of the disassembly. To avoid
damage to the seal surfaces, hold the body horizontally
across its diameter, not across the end faces.
4. Remove the seats and body seals.
5. Remove the handle nut and handle. Remove the
gland nut.
6. To remove the ball, rotate the stem so the ball is fully