Bray FLOW-TEK Series Bedienungsanleitung

FLOW-TEK

CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

BRAY.COM THE HIGH PERFORMANCE COMPANY

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

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For information on this product and other Bray products please visit us at our web page - www.bray.com

CONTENTS

1.0 Definition of Terms 2

2.0 Scope 2

3.0 Caution 2

4.0 Warehousing, Storage, Installation And Operations 3

5.0 Troubleshooting 6

6.0 Disassembly 7

7.0 Assembly 10

8.0 Gearbox 12

9.0 Disclaimer 13

10.0 Short and Long-Term Storage 14

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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 of 15

READ AND FOLLOW THESE INSTRUCTIONS CAREFULLY.

SAVE THIS MANUAL FOR LATER USE.

1.0 DEFINITION OF TERMS

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in

minor or moderate injury.

NOTICE

Used without the safety alert symbol, indicates a potential situation which, if not

avoided, may result in an undesirable result or state, including property damage.

2.0 SCOPE

2.1 This manual is prepared for users to obtain useful information to install,

operate and perform maintenance on our valves.

3.0 CAUTION

3.1 It is important to ensure safe operation of our valves that you read,

understand, and follow all the contents of this manual, including all

safety cautions and warnings to avoid personal injury or property

damage. DO NOT install, operate, or maintain valve without being fully

trained and qualiﬁed in valve installation, operation, and maintenance.

If you have any questions about this manual, contact Bray International,

Inc. before proceeding.

3.2 Always wear protective gloves, clothing, and eye wear when performing

any installation operations to avoid personal injury. Personal injury or

equipment damage caused by sudden release of pressure or bursting of

pressure retaining parts might result if service conditions exceed those

for which the product was intended. Check with your process or safety

engineer for any additional measures that must be taken to protect

against process media.

3.3 No repairs, such as welding and painting touch up, should be

conducted when the valve is operating online.

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

3 of 15

CAUTION

Ball valves can trap pressurized ﬂuids in ball cavity when closed. If the valve

has been used to control hazardous media, it must be decontaminated before

disassembly. It is recommended that the following steps are taken for safe

removal and reassembly:

> Relieve the line pressure

> Place valve in half-open position and flush the line to remove any hazardous

material from valve

> When being repaired offline, the valves closest to either end of the valve being

repaired should be opened first, in order to relieve the line pressure

3.4 After being removed from the pipeline, the valve should be vertically

placed on the workbench for disassembly. In doing so, position the

valve so that its inlet port faces the work surface to drain and remove

any remaining liquid medium or rigid granules possibly left over inside

the valve cavity.

4.0 WAREHOUSING, STORAGE, INSTALLATION AND

OPERATIONS

4.1 Warehousing

4.1.1 For acceptance inspection and testing before warehousing, it shall be

carried out according to API 6D, API 598 or PO requirements;

4.1.2 For the trunnion ball valves, the pressure tests shall be performed to

the pressure-temperature rating of the valve body material.

4.1.3 The order of testing should be:

> Shell

> High Pressure Hydrostatic Seat Closure

> Low Pressure Pneumatic Seat Closure

4.1.4 For shell test, no observable leakage is allowed.

CAUTION

After shell test, the ﬂuid can be remained but the pressure shall be relieved

before proceeding seat tests.

4.1.5 For bi-directional ball valves, seat leakage shall be monitored from each

seat via the valve body cavity vent or drain connection, where provided.

4.1.6 For valves without a body-cavity vent or drain connection, seat leakage

shall be monitored from the respective downstream end of the valve.

4.1.7 If the testing procedure and inspection method different than the

standard procedure, the PO requirements shall be followed.

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

4 of 15

4.1.8 The shell test pressure shall be 1.5 or more times the pressure rating

determined in accordance with Pressure-Temperature Rating for

material at 38 °C (100 °F) in ASME B16.34-2009.

4.1.9 For testing during, please see Table 1 and 2 (API 6D reference).

Table 1 - Minimum Duration of Hydrostatic Shell Tests

Valve Size DN Valve Size NPS Test Duration Minutes

15 to 100 ½to 4 2

150 to 250 6 to 10 5

300 to 450 12 to 18 15

≥ 500 ≥ 20 30

Table 2 - Minimum Duration of Hydrostatic Seat Tests

Valve Size DN Valve Size NPS Test Duration Minutes

15 to 100 ½to 4 2

≥ 150 ≥ 6 5

4.2 Storage and Protection

4.2.1 The valve must be stored in a dry and ventilated space

4.2.2 During the storage, the valve should be kept in a full-open state and

then periodically closed and opened to prevent valve blockage.

4.2.3 For valves to be stored for a longer period of time, anti-rust agents shall

be applied to un-painted surface to prevent rusting.

4.2.4 Valves stored for long periods should be subject to scheduled

inspections, which include:

> removal of foreign substances, rust, or stains

> re-application of a coating of rust preventive oil (grease) on any non-

machined surfaces

> opening and closing of the valve to verify proper and agile operation

> visually inspect to assure that it is free of rust which could cause

jamming during operation. After the inspection, seal the valve and

store it back in place.

4.3 Installation

4.3.1 Before valve installation, the operator must check and make sure the

information contained on the valve marking and nameplate is consistent

with the working condition, medium and pressure requirements.

4.3.2 Before installation, remove the end connection seal covers and make

sure that the ﬂange or butt-weld ends are free of rust or dirt.

4.3.3 During installation, keep the valve in the full-open position.

4.3.4 For uni-directional single seated and bi-directional double seated

valves, the direction of valve installation shall comply with the direction

mark on the valve body.

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

5 of 15

4.3.5 When lifting the valve with chains, the operation device should not

touch the chains. At the same time, avoid the angle between the chains

to be less than 60 degrees, see Figure 1.

CAUTION

NEVER use hand wheels, gearbox, actuator or any other protruding part of the

valve as a support for lifting the valve. Lifting lugs, if provided, are attached to

balance the weight. Never use just one lifting lug for lifting.

4.3.6 The valve should be mounted in its natural state (i.e. without additional

fabrication modiﬁcations, such as piping or supports) to prevent undue

and improper installation stresses which will be generated by added

pipe or supports.

4.3.7 Before the installation of a threaded valve, a socket-weld valve or a

butt-weld valve, make sure that there is no rust or dirt remaining on the

thread, socket, or butt-weld end. For weld connections, greasy dirt left

over on the weld end must be cleaned.

4.3.8 When tightening ﬂange bolts, use the crisscross method and

gradually tighten each nut, repeating several times, to ANSI or gasket

manufacturer’s speciﬁcations. Excessive tightening can cause damage

and/or leakage to the end ﬂanges or body-to-body end joint.

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

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4.3.9 In high temperature applications, valves and piping can get very hot

causing possible skin injury when in contact. Proper pipe and valve

insulation is suggested. An eye-catching warning should be provided to

avoid scalding or burns in such applications.

4.3.10 After installation, the valve should be fully opened for pipe purging and

pressure testing so as to examine the sealing performance of valve,

valve connection ends and the entire pipeline system as well as the

valve operation.

4.3.11 For the bare stem valves without actuator, when the actuator is being

installed, please do not impose the high downward install stress from

the stem side to avoid high levels of impact strength from stem to ball,

and make the ball supporting part lose effectiveness, diverge to the

middle and cause leakage.

4.4 Operation

4.4.1 The practical condition intending to use valves must conform to the

requirements speciﬁed on nameplate and in the operation instruction.

4.4.2 DO NOT impose any external stress on the pipe where the valve is

mounted during operation, such as hanging or supporting any weight.

5.0 TROUBLESHOOTING

Problems Possible Causes Possible Remedies

Body-to-Bonnet

connection leaks.

Connecting bolts are not

evenly tightened up

Tighten up bolts evenly.

Gasket is broken or invalid Replace gasket.

Stem leaks Packing and gasket are

damaged

Replace with new packing

and gasket.

Seat leaks The seat spring exceeds

its designed service life

and generates insufficient

pre-tightening force

Check seat bracing ring and

replace supporting spring.

The ball or seal face is

deformed

It can’t be used to control

the flow any more except

opening.

Valve isn’t fully closed Close the valve completely.

Seating surface is damaged Use the emergency grease

fitting to block up the

leakage and then arrange

the timing for inspecting

the damaged seal face

according to the actual

operation of the pipeline.

Valve can’t operate

normally

Actuator is damaged Repair and replace the

actuator.

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

7 of 15

6.0 DISASSEMBLY

No Part Name No Part Name No Part Name

1 Body 14 O-Ring 27 Packing

2 Bolt 15 Trunnion 28 Bushing

3 Nut 16 Gasket 29 Bolt

4 Spring 17 Plug 30 Nut

5 O-Ring 18 Hex Socket Screw 31 Bolt

6 Seat Insert 19 Gland 32 Nut

7 Seat 20 Bearing 33 Yoke

8 O-Ring 21 Upper Stem 34 Nut

9 Gasket 22 Gland 35 Bolt

10 Cover 23 Gasket 36 Gearbox

11 Ball 24 O-Ring 37 Grease Fitting

12 Anti-static Device 25 Gland 38 Vent Valve

13 Bearing 26 Hex Socket Screw 39 Drain Plug

Before taking any step to remove the valve from the

pipeline, make sure you have read and understand all

instructions as prescribed in “Caution”. Key steps of valve

removal are shown below:

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

8 of 15

6.1 Before removing the actuator, fully close the valve, see Figure 3;

6.2 After the valve is fully closed, remove valve actuating

parts and sealing parts, like actuator (12), top-mounted

ﬂange, stem (9), packing and packing case, and lay them

out in order on the workbench to prevent the loss of

parts, see Figure 4

FLOW-TEK CAST STEEL TRUNNION BALL VALVE

Installation, Operation and Maintenance Manual

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.

9 of 15

6.3 Place the valve vertically on a rubber-cushioned surface

to prevent the ﬂange face from being damaged, see

Figure 5

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