125368226-Manually-Actuated-FL-and-FLS-Gate-Valves

Operation and Maintenance Manual
Manually Actuated
FL and FLS Gate Valves
TC148
All the information contained in this manual is the exclusive property of
Cameron. Any reproduction or use of the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden
without the written permission of Cameron or its authorized agent.
Initial Release A1
April 1992
Revision B1
April 1994
Revision C1
June, 1997
Copyright ©1997 all rights reserved
by
Cooper Cameron Corporation
Cameron Division
TC148
Rev C1 6/97
2
PREFACE
The procedures included in this book are to be performed in conjunction with
the requirements and recommendations outlined in API Specifications. Any
repairs to the equipment covered by this book should be done by an
authorized Cameron service representative. Cameron will not be responsible
for loss or expense resulting from any failure of equipment or any damage
to any property or injury or death to any person resulting in whole or in part
from repairs performed by other than authorized Cameron personnel. Such
unauthorized repairs shall also serve to terminate any contractual or other
warranty, if any, on the equipment and may also result in the equipment no
longer meeting applicable requirements.
File copies of this manual are maintained. Revisions and/or additions will be
made as deemed necessary by Cameron. The drawings in this book are not
drawn to scale, but the dimensions shown are accurate.
P.O. Box 1212
Houston, Texas 77251-1212
ph: 713-939-2211
http://www.coopercameron.com
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CONTENTS
I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Description and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
C. Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
D. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
A. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. Body Cavity Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
D. Thrust Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
III. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
IV. Bonnet Grease Fitting Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. Valves 10,000 psi WP and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
B. Valves 15,000 psi WP and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
V. Stem Shear Pin and Thrust Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . 17
A. Removal of the Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
B. Installation of the New Thrust Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
VI. Stem Packing Replacement with Pressure in the Valve. . . . . . . . . . . . . . . . . . 18
A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
B. Installation of the New Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
C. Gate and Seat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
VIII. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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I. GENERAL INFORMATION
A. Description and Features
The FL or FLS gate valve is a full-bore through-conduit valve designed and
manufactured in accordance with API 6A and NACE MR-01-75. It is available
in standard double flange, threaded-end, and special block body configurations.
The following are standard features of the FL and FLS gate valves:
1. Sealing at the gate-to-seat and the seat-to-body is metal-to-metal.
2. The simplified gate and seat assembly has a minimum number of parts.
One-piece seats and slab gate ensure reliable sealing and simplify field
service. The modified Acme gate-to-stem thread allows the gate to move
back and forth, or float, to seal against the seat.
3. The gate and seat assembly seals in both directions, and the gate and seats
can be reversed for increased life.
4. The stem shoulder can be backseated against the bonnet to isolate the
stuffing box, which allows field-replacement of the stem packing while the
valve is under pressure.
5. The non-rising stem prevents a cavity pressure increase or displacement
of cavity lubricant.
6. All FL and FLS valves have a specially designed, metal-to-metal sealing
grease fitting which contains a check valve. The stem, gate, and seat are
lubricated through the grease fitting which is located on the downstream
side of the stem backseat for safety. No sealant or lubrication ports extend
directly into the valve cavity.
7. The seal between the valve body and bonnet is a pressure-energized,
BX-style metal bonnet gasket on 10,000 and 15,000 psi WP valves. Valves
for 3000 and 5000 psi WP use a flat compression-type metal gasket.
8. API 6A Materials Classes and Temperature Classes are available, and
other special trims are available upon request. Reduced-hardness bonnet
bolting can be supplied for most sizes and pressures without downrating
the working pressure.
9. With minor modifications, FL and FLS valves can meet or exceed API 6FA
fire safety requirements.
10. Special non-elastomeric stem packing designs can extend the standard
temperature rating of the FL or FLS Gate Valve up to 350° F, or down to
-75° F. These temperature ratings may not be available in all working
pressures.
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11. An optional add-on torque multiplier is available for larger FL and FLS valves
to provide easier operation.
12. See the valve assembly bill-of materials for materials and descriptions of
valve components.
B. Operation Instructions
A gate valve should always be in either the full-open or full-closed position.
Leaving the gate partially open or throttling through the valve could cause
damage to the gate.
The valve is opened by turning the handwheel counterclockwise (to the left) until
it stops. Turning the handwheel back to the right 1/4 turn will then relieve any
stress in the stem,and is, therefore, recommended practice. Initial torque required to open the valve is given in Table I.
The valve is closed by turning the handwheel clockwise (to the right) until it stops,
and then backing off (counterclockwise) 1/2 to 3/4 turn. The number of turns
required to move the valve from full open to full closed is given in Table I.
Table I: Operating Requirements
2000 - 3000 psi WP
5000 psi WP
Valve Bore Size
21/16" 29/16" 31/8" 41/16" 51/8" 63/8" 21/16" 29/16" 31/8" 41/16" 51/8" 63/8"
Expected Opening
Torque, Lubricated Valve,
15
20
25
30
45
80
20
25
35
50
75
140
ft-lb
Maximum Opening
30
40
60
80
130
235
45
65
95
135 220 395
Torque, Severe Service,
ft-lb
Total Number of Turns,
121/3 151/8 181/8 231/4 271/2 333/4 121/3 151/8 181/8 231/4 271/2 333/4
Full-open to Full-closed
10,000 psi WP
Valve Bore Size
Expected Opening
Torque, Lubricated Valve,
ft-lb
Maximum Opening
Torque, Severe Service,
ft-lb
Total Number of Turns,
Full-open to Full-closed
13
1
15,000 psi WP
9
1
1
1
13
1 /16"
2 /16"
2 /16"
3 /16"
4 /16"
5 /8"
1 /16"
21/16"
29/16"
31/16"
30
35
50
65
110
260*
50
60
100
125
80
85
130
170
320
690*
125
155
265
335
121/3
121/3
151/8
181/8
231/4
29
121/3
121/3
153/4
227/8
*Optional torque multiplier recommended. See manual #SD-1792.
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C. Dimensional Data
B
F
3-3/4"
E
C
D
Figure 1
A
SD-10489-99
Table II: Dimensional Data - 2000 psi WP
Item
A
B
C
D
E
F
Description
End-to-End, Flanged (Ring Joint)
Extreme Width of Body
Center of Port to Top of Stem Adapter
Center of Port to Bottom of Body
Center of Port to Top of Handwheel Rim
Handwheel OD
Weight (Flanged)
21/16"
29/16"
31/8"
41/8"
61/8"
115/8"
61/8"
13"
51/4"
153/8"
14"
160 lb
131/8"
71/8"
3313/16"
6"
161/8"
14"
200 lb
141/8"
73/4"
1613/16"
71/8"
191/16"
14"
240 lb
171/8"
93/4"
187/16"
91/8"
2011/16"
14"
350 lb
221/8"
123/8"
223/4"
127/8"
24"
181/2"
800 lb
Table III: Dimensional Data - 3000 psi WP
Item
A
A
B
C
D
E
F
Description
End-to-End, Threaded
End-to-End, Flanged (Ring Joint)
Extreme Width of Body
Center of Port to Top of Stem Adapter
Center of Port to Bottom of Body
Center of Port to Top of Handwheel Rim
Handwheel OD
Weight (Flanged)
TC148
Rev C1 6/97
21/16"
29/16"
31/8"
41/8"
51/8"
61/8"
105/8"
145/8"
63/4"
13"
55/8"
153/8"
14"
170 lb
123/8"
165/8"
75/8"
3313/16"
61/2"
161/8"
14"
220 lb
135/8"
171/8"
71/2"
1613/16"
73/8"
191/16"
14"
260 lb
201/8"
101/2"
187/16"
91/8"
2011/16"
181/2"
450 lb
241/8"
21"
215/16"
113/8"
229/16"
24"
750 lb
241/8"
123/4"
223/4"
127/8"
24"
24"
1000 lb
9
Table IV: Dimensional Data - 5000 psi WP
Item
A
A
A
B
C
D
E
F
Description
End-to-End, Threaded
End-to-End, Flanged (Ring Joint)
End-to-End, Butt Weld
Extreme Width of Body
Center of Port to Top of Stem Adapter
Center of Port to Bottom of Body
Center of Port to Top of Handwheel Rim
Handwheel OD
Weight (Flanged)
21/16"
29/16"
31/8"
41/8"
51/8"
61/8"
105/8"
145/8"
7"
151/8"
55/8"
173/8"
14"
175 lb
123/8"
165/8"
83/16"
1515/16"
61/2"
181/8"
14"
230 lb
135/8"
185/8"
91/4"
1613/16"
73/8"
191/16"
181/2"
360 lb
215/8"
211/2"
1013/16"
187/16"
91/8"
2011/16"
181/2"
520 lb
285/8"
213/4"
215/16"
113/8"
239/16"
24"
800 lb
29"
141/8"
223/4"
127/8"
24"
24"
1160 lb
113/16"
21/16"
29/16"
31/16"
41/16"
51/8"
181/4"
91/16"
151/8"
53/4"
173/8"
14"
250 lb
201/2"
93/8"
151/8"
57/8"
173/8"
181/2"
275 lb
221/4"
913/16"
1513/16"
613/16"
181/8"
181/2"
370 lb
243/8"
101/4"
167/8"
81/16"
181/16"
24"
480 lb
263/8"
1213/16"
1911/16"
101/16"
2015/16"
24"
880 lb
29"
231/2"
237/8"
131/8"
251/4"
24"
1750 lb
Table V: Dimensional Data - 10,000 psi WP
Item
A
B
C
D
E
F
Description
End-to-End, Flanged (Ring Joint)
Extreme Width of Body
Center of Port to Top of Stem Adapter
Center of Port to Bottom of Body
Center of Port to Top of Handwheel Rim
Handwheel OD
Weight
Table VI: Dimensional Data - 15,000 psi WP
Item
A
B
C
D
E
F
Description
End-to-End, Flanged (Ring Joint)
Extreme Width of Body
Center of Port to Top of Stem Adapter
Center of Port to Bottom of Body
Center of Port to Top of Handwheel Rim
Handwheel OD
Weight
TC148
Rev C1 6/97
113/16"
21/16"
29/16"
31/16"
18"
97/8"
151/8"
57/8"
173/8"
181/2"
275 lb
19"
97/8"
151/8"
61/8"
173/8"
181/2"
300 lb
21"
111/2"
173/16"
75/16"
199/16"
181/2"
560 lb
239/16"
139/16"
2015/16"
91/4"
223/16"
24"
890 lb
10
D. Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12*
13
14
15
16
17
18
19
20
21
22
23
24*
25
26
1
4
2
6
3
7
5
5
8
9
6
5
5
10
12
11
13
14
15
16
Description
Handwheel
Grease Fitting
Bearing Cap
O-Ring
Race
Bearing
O-Ring
Stem Adapter
Stem Shear Pin
Packing Gland
Stem Packing
Packing Backup Ring
Bonnet Nut
Bonnet Stud
Bonnet
Grease Injection Fitting
Bonnet Seal Ring
Stem
Gate
Seat
Seal Ring, OD
Seal Ring, ID (FLS Only)
Retainer Plate
Dowel Pin
Body
Nameplate
*Not Supplied in all sizes and pressures.
18
19
21
22
20
23
17
24
26
25
Figure 2
Typical FL or FLS Valve
SD-10387-99
TC148
Rev C1 6/97
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II. PERIODIC MAINTENANCE
A. Lubrication
1. Recommended body cavity lubricant.
a. For normal operation, use Cameron valve lubricant CI-14 or TF-41,
greases not affected by water or temperatures ranging from -20° to +250°
F.
b. For continuous service below 0° F, use a low temperature grease such
as “arctic grease” NS-14.
2. Recommended stem bearing lubricant
a. For normal operation, use Cameron valve lubricant CI-14 or TF-41,
greases not affected by water or temperatures ranging from -20° to +250°
F.
b. For continuous service below 0° F, use a low temperature grease such
as “arctic grease” NS-14.
B. Lubrication Charts
Table VII: Grease Volume Requirements
Bore Size
(in.)
Pressure Rating
113/16
21/16
29/16
29/16
31/8
31/16
31/16
41/8
41/16
51/8
51/8
61/8
63/8
All
All
To 10,000
15,000
To 5000
10,000
15,000
To 5000
10,000
5000
10,000
To 5000
To 5000
Lubricant Volume
Required (cu in.)
38
43
79
93
114
114
155
245
243
312
461
583
583
Lubricant Weight
(lb)
1.5
1.7
3.2
3.7
4.6
4.6
6.2
9.8
9.7
12.5
18.5
23.3
23.3
Approximate
Follower
Plate Travel (in.)
.5
.7
1.3
1.6
1.9
1.9
2.6
4.2
4.1
5.3
7.8
9.9
9.9
SD-4130
TC148
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Table VIII: Lubricant Selection
P
P
F
F
P
Arctic
NS-14
E
E
P
P
F
F
P
Diesel
Resistant
High
Temperature
High
Temperature
E - Execllent
G - Good
SS-14 or
TS-41
E
P
E
P
G
G
G
HT-14S
G
F
P
E
F
F
P
Moly 101
G
P
P
E
G
F
P
o
F - Fair
P - Poor
Mineral
Spirits
Mineral
Spirits
Alcohol
Mineral
Spirits
Mineral
Spirits
400 lb Drum
Very High CO2
P
120 lb Drum
With Gas Well Condensates
E
25 lb Pail
With H2S (Sour Crude or Gas)
CI-14 or
TF-41
Quantities (By Part Number)
Available on a Standard Order Basis
5 lb Can
High Temp. RT to +650 F
Standard
o
Diesel
Solvent
Low Temp. to -75 F
Operational Properties
(Per Pound)
Lubricant
Name
Standard Crude
Service
700149
700667
700668
700669
700670
700123
700671
700672
700673
700674
700150
700675
700676
700677
700678
700217
700679
700680
700681
700682
710194
700679
700680
700681
700682
Example for Ordering: Order Part Number 700672 for 25 lb of NS-14
SD-4185
C. Body Cavity Lubrication
1. Normal Operating Conditions
Note: Cameron lubricates gate valves on assembly. Lubricate the body cavity after ten
operating cycles. One cycle equals opening and closing the valve one time. The
service interval can vary according to application, fluids used, and well conditions.
If pressure is equalized across the valve before the valve is opened, the service
interval can be extended. If the valve is removed from service, lubricate the body
cavity before returning it to the line.
a. Remove the grease fitting cap located on the bonnet flange OD.
b. Using either a bucket-type gun, P/N 19873-03, or hand-held type, P/N
19873-01, connect the grease gun coupler to the grease fitting.
c. Pump the appropriate amount of lubricant into the body cavity. Refer to
Part I, Paragraph B.
2. Unusual Temporary Operating Conditions
If it becomes necessary to cement through, acidize through, or subject the
valve to any other unusual service, proceed as follows:
a. Lubricate the valve body cavity before it is put into operation.
TC148
Rev C1 6/97
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b. Flush the valve with the appropriate neutralizing fluid in the line.
c. Operate the valve with fresh water or appropriate neutralizing fluid in the
line.
d. Lubricate the valve body cavity.
D. Thrust Bearing Lubrication
Note: Lubricate the thrust bearings as often as required to ensure smooth valve operation.
1. Using a hand-held grease gun, P/N 19873-01, connect the grease gun fitting
to the hydraulic grease fittings with a hydraulic coupler.
2. Pump lubricant into the fittings until clean grease appears at the bleed port
on the opposite side of the bearing cap.
III. TROUBLESHOOTING
Symptom
Fluid leaks past the gate and seat
assembly.
Cause
1. Gate or seats are worn.
2. Handwheel is not backed off.
Fluid leaks around the valve stem. Stem packing is worn.
Action
Replace the gate or seats.
Back off the handwheel 1/4 turn.
Replace the stem packing.
Fluid leaks at the bonnet flange.
1. Bonnet seal ring is worn.
2. Bonnet or body ring groove is
damaged.
Replace the bonnet seal ring.
Return the valve to Cameron for
repair.
Fluid leaks from the bonnet
grease fitting.
Check valve inside the grease
fitting is worn.
Replace the grease fitting.
Lubricate the thrust bearings.
Handwheel is hard to turn.
1. Thrust bearings have lost
lubricant.
2. Thrust bearings are corroded.
3. Gate and stem threads have
lost lubricant.
Handwheel turns without opening
or closing the valve.
Stem shear pin is sheared.
Replace the stem shear pin.
Replace the thrust bearings.
Lubricate the gate and stem
through the bonnet grease fitting.
Caution: When a valve is used in the lower master valve position, on the outlet of a BOP
or any other application in which it is the last surface barrier, precautions should
be taken to ensure sub-surface safety barriers are in place and functioning. If
valve bonnet maintenance is to be performed such as stem packaging replacement, bearing replacement or shear pin replacement consideration should be
given with respect to number of barriers required by the customer and the local
statutory requirements.
IV. BONNET GREASE FITTING REPLACEMENT
A. Valves 10,000 psi WP and Below
1. Backseat the valve
TC148
Rev C1 6/97
14
a. Close the valve fully.
b. Loosen the bearing cap four complete turns.
c. Turn the handwheel clockwise (the closing direction) until the gate firmly
contacts the bottom of the cavity and the stem moves outward, contacting
the internal backseat shoulder.
d. Bump the handwheel in the closing direction.
2. Test the effectiveness of the
backseat. Refer to Figure 3.
a. Remove the grease fitting
cap.
Bonnet
1/8" Diameter Pin
b. Trip the ball in the grease fitting check valve by inserting
a 1/8" diameter by 3/4" long
pin into the run of the fitting.
c. Replace the cap slowly until
the ball in the fitting is unseated and the pressure
trapped by the backseating
process is released.
Pressure
In Bonnet
Grease
Fitting
Body
Grease
Fitting
Cap
Pressure
Bleed By
Hex
SD-10268-99
Figure 3 Low Pressure Grease Fitting
d. If pressure escapes quickly and then stops, the backseat is effective.
Proceed to step 3.
e. If Pressure continues to escape, the backseat is ineffective.
1) Backseat the valve again. Repeat steps 1 and 2.
2) If the backseat continues to be ineffective, contact a Cameron representative.
3. Remove the grease fitting from the valve bonnet.
4. Install a new grease fitting.
Caution: Installing the fitting with the cap in place could damage the cap. Do not install
the fitting with the cap in place.
5. Un-backseat the valve.
a. Tighten the bearing cap. Torque to approximately 25 ft-lb.
b. Turn the handwheel counterclockwise (opening direction) one full turn
while simultaneously tightening the bearing cap.
TC148
Rev C1 6/97
15
c. Tighten the bearing cap to approximately 200 ft-lb.
B. Valves 15,000 psi WP and Above
Note: The standard grease fitting for
15,000 psi WP FL valves is a special
metal-sealing, high pressure fitting,
containing a check valve. The bonnet port housing this fitting is a special preparation without pipe threads
which accepts only this type of fitting.
Important: DO NOT use Teflon tape or
thread sealant on these fittings.
Grease
Fitting
Body
Bonnet
Pressure
In Bonnet
Pressure
Bleed By
1. Backseat the valve.
Grease Fitting Gland
Hex
a. Close the valve fully.
b. Loosen the bearing cap
four complete turns.
Grease
Fitting
Cap
SD-10267-99
Figure 4 High Pressure Grease Fitting
c. Turn the handwheel clockwise (the closing direction) until the gate firmly
contacts the bottom of the cavity and the stem moves outward, contacting
the internal backseat shoulder.
d. Bump the handwheel in the closing direction.
2. Test the effectiveness of the backseat. Refer to Figure 4.
a. Remove the grease fitting cap.
b. Place a wrench on the hex preparation of the fitting gland and back out
the fitting approximately one turn. This procedure unseats the metal seal
and vents any pressure on the fitting.
c. If pressure escapes quickly and then stops, the backseat is effective.
Proceed to step 3.
d. If pressure continues to escape, the backseat is ineffective.
1) Backseat the valve again. Repeat steps 1 and 2.
2) If the backseat continues to be ineffective, contact a Cameron representative.
3. Remove the grease fitting from the valve bonnet.
TC148
Rev C1 6/97
16
4. Remove the cap from a new grease fitting and install the fitting in the bonnet.
Torque to 80 to 100 ft-lb.
5. Install and tighten the cap on the fitting.
Caution: Installing the fitting with the cap in place prevents the fitting from seating and
could cause damage to the cap. Do not install the fitting with the cap in place.
6. Un-backseat the valve.
a. Tighten the bearing cap. Torque to approximately 25 ft-lb.
b. Turn the handwheel counterclockwise (opening direction) one full turn
while simultaneously tightening the bearing cap.
c. Tighten the bearing cap to approximately 200 ft-lb.
V. STEM SHEAR PIN AND THRUST BEARING REPLACEMENT
Note: The stem thrust bearings can be replaced while the valve is under pressure in the
line.
A. Removal of the Thrust Bearings
1. Loosen the bearing cap, using a 24" pipe wrench. After two or three turns,
the cap will rotate freely by hand.
Caution: If the cap does not rotate freely after three turns, the packing gland may be
moving outward with the bearing cap. This can be checked by tapping on the
stem adaptor so it moves relative to the bearing cap. If the stem adaptor does
not move inward or continues to back out with the bearing cap, DO NOT remove
the cap. Tighten the cap and contact a Cameron representative.
2. If the bearing cap rotates freely, remove the cap from the bonnet.
3. Using a punch, drive the stem shear pin from the stem adapter, ensuring
that the adapter is not damaged.
4. Remove the adapter from the stem.
5. Remove both sets of bearings and bearing races from the stem adapter.
6. Discard any pitted, cracked, or damaged bearings or races.
7. Replace the stem adapter if either of the bearing surfaces on the adapter
shoulder is damaged.
B. Installation of the New Thrust Bearings
1. Remove the new bearings from the protective packaging.
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2. Pack the bearings with clean grease.
3. Place each bearing between a pair of carefully cleaned races.
4. Carefully clean the stem adapter.
5. Install one set of bearings and races over the bottom of the adapter and
one set over the top of the adapter.
Note: The adapter O-ring may be removed temporarily to allow for the installation of the
top bearing and race assembly.
6. Insert the stem adapter over the end of the stem and align the pin hole in
the adapter with the hole in the stem.
7. Using a punch, drive in the stem pin and ensure that the pin does not
protrude over the OD of the adapter shoulder.
Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer.
8. Replace the stem adapter O-ring if necessary.
9. Inspect the bearing cap to ensure that an extra race, held by grease tension,
is not retained inside.
10. Clean the bearing cap and lubricate the threads.
11. Install the cap, and tighten to approximately 200 ft-lb.
12. Rotate the stem adapter counterclockwise to ensure that the gate is off the
bottom of the body. This procedure will confirm that the stem backseating
shoulder is not contacting the bonnet shoulder.
13. Inject grease through the bearing cap grease fittings until the excess grease
passes through the bleed port.
VI. STEM PACKING REPLACEMENT WITH PRESSURE IN THE VALVE
A. Removal of the Stem Packing
Note: If there is no pressure in the valve, proceed to step 3.
1. Backseat the valve.
a. Close the valve fully.
b. Loosen the bearing cap four complete turns.
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c. Turn the handwheel clockwise (the closing direction) until the gate firmly
contacts the bottom of the cavity and the stem moves outward, contacting
the internal backseat shoulder.
d. Bump the handwheel in the closing direction.
2. Test the effectiveness of the backseat.
a. Valves 10,000 psi WP and Below. Refer to Figure 3.
1) Remove the bonnet grease fitting cap.
2) Trip the ball in the grease fitting check valve by inserting an 1/8“
diameter by 3/4” long pin into the run of the fitting.
3) Replace the cap slowly until the ball in the fitting is unseated and the
pressure trapped by the backseating process is released.
4) If pressure escapes quickly and then stops, the backseat is effective.
Proceed to step 3.
5) If pressure continues to escape, the backseat is ineffective.
a) Backseat the valve again. Repeat steps 1 and 2.
b) If the backseat continues to be ineffective, contact a Cameron
representative.
b. Valves 15,000 psi WP and Above. Refer to Figure 4.
1) Remove the grease fitting cap.
2) Place a wrench on the hex preparation of the fitting gland and back
out the fitting approximately one turn. This procedure unseats the
metal seal and vents any pressure on the fitting.
3) If pressure escapes quickly and then stops, the backseat is effective.
Proceed to step 3.
4) If pressure continues to escape, the backseat is ineffective.
a) Backseat the valve again. Repeat steps 1 and 2.
b) If the backseat continues to be ineffective, contact a Cameron
representative.
3. Remove the handwheel and bearing cap.
4. Remove the cap from the bonnet.
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5. Using a punch, drive the stem shear pin from the stem adapter, ensuring
that the adapter is not damaged.
6. Remove the adapter from the stem.
7. Remove both sets of bearings and bearing races from the stem adapter.
8. Loosen the packing gland.
9. Ensure that the threads on the bonnet neck OD are not damaged.
10. Remove the packing gland.
11. Remove the stem packing and backup ring (if applicable).
a.Use packing sleeve P/N 21168 for 1" stem size and packing sleeve P/N
233842 for 11/4" stem size.
1) Thread the packing sleeve into the bonnet packing gland preparation
until the sleeve bottoms out.
2) Using a grease gun attached to the bonnet grease fitting, pump the
packing out into the recessed area of the packing sleeve.
3) Remove the sleeve from the bonnet.
b. If a packing sleeve is not available, remove the stem packing by one of
the following methods:
1) Pump the packing out with grease until the grease bypasses or the
packing refuses to extrude further.
2) Pull the packing out with a corkscrew.
Caution: Do not damage the stem or packing bore.
B. Installation of the New Packing
1. Clean the grease from the stuffing box bore so that a hydraulic lock will not
prevent the installation of new packing.
2. Inspect the stuffing box to ensure that the bore is clean and free of pits or
scars.
3. Inspect the stem to ensure that the surface is free of burrs and pits.
4. Apply a light coat of grease to:
a. The stem
b. The stuffing box bore
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c. The ID and OD of the stem packing
d. The nose and threads of the packing gland.
5. Lightly grease the new stem packing. Install it over the stem and into the
bonnet as follows:
a. J packing or U packing: Install with rounded nose facing pressure.
b. Varipak packing: Install with open end facing pressure.
c. HT-20 packing: Call Cameron service. (Special tools required; not user
replaceable).
6. Using the packing gland as a pushing tool, push the packing into the stuffing
box.
7. Remove the packing gland and lubricate the stem OD. If a packing back-up
ring is required, install it over the stem.
8. Install the packing gland and apply approximately 200 ft-lb of torque,
ensuring that the bonnet threads are not damaged.
9. Inspect the bearings and bearing races on the stem adapter for pits, scores,
or cracks. Replace if damaged.
10. Pack the bearings with grease.
11. Place each bearing between a pair of carefully cleaned races.
12. Carefully clean the stem adapter.
13. Install one set of bearings and races over the bottom of the adapter and
one set over the top of the adapter.
Note: The adapter O-ring may be removed temporarily to allow for the installation of the
top bearing and race assembly.
14. Insert the stem adapter over the end of the stem and align the pin hole in
the adapter with the hole in the stem.
15. Using a punch, drive in the stem pin and ensure that the pin does not
protrude over the OD of the adapter shoulder.
Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer.
16. Replace the stem adapter O-ring if necessary.
17. Inspect the bearing cap to ensure that an extra race, held by grease tension,
is not retained inside.
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18. Clean the bearing cap and lubricate the threads.
19. Install the cap, and torque to 200 ft-lb.
20. Rotate the stem adapter counterclockwise to ensure that the gate is off the
bottom of the body. This procedure will confirm that the stem backseating
shoulder is not contacting the bonnet shoulder.
21. Inject grease through the bearing cap grease fitting until the excess grease
passes through the bleed port.
22. Lubricate the body cavity. Refer to Part I.
VII. GATE AND SEAT REPLACEMENT
A. Gate and Seat Disassembly
1. Isolate the valve from the line pressure.
2. Release the cavity pressure by bleeding the bonnet grease fitting.
3. Fully open the valve to ensure that the stem is completely within the gate
neck.
4. Remove the bonnet nuts.
5. Support the bonnet and turn the handwheel clockwise until the stem
completely backs out of the gate.
6. Remove the bonnet assembly.
7. Pull the gate from the body.
8. Remove the seats.
Note: If the seats are stuck, insert a screwdriver in the groove on the OD of the seats and
pry out the seats.
9. Remove the retainer plate from the bottom of the body cavity.
10. Flush the body cavity thoroughly with a suitable solvent and wipe clean with
a rag.
B. Gate and Seat Inspection
1. Inspect the cavity parts for damage.
a. Ensure that the retainer plate is not bent, twisted, or distorted.
Important: Solid material should not be built up on the retainer plate surfaces.
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b. Ensure that the seal rings are not damaged.
c. Ensure that the seats are not cut or damaged.
d. Ensure that the gate is not cut or damaged.
2. Replace any damaged parts.
3. Ensure that the body cavity is free of all foreign matter such as solid
particles, grit, trash, etc.
4. Clean the body cavity with a suitable cleaning solvent.
5. Apply a thin coat of clean grease to the body cavity, gate, retainer plate,
seats, and seat seal rings.
6. Install the U-shaped retainer plate in the bottom of the body cavity. The flat
center part of the retainer plate goes against the cavity bottom, and the
semi-circular cut-outs must be aligned with the seat pockets.
C. Gate and Seat Assembly
1. Install the seal rings into the face groove(s) located in the seats.
Note: The FL valve uses one seal ring per seat; the FLS uses two per seat.
2. Install the seats into the seat pockets.
Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal
face. Do not apply more than a very thin film of grease to the back face of the seat
and seal ring(s) or the seal face on the body seat pocket.
3. Install the gate into the cavity between the seats.
4. Push the gate all the way to the bottom of the cavity and pack the remaining
space with grease.
5. Remove the seal ring from the bonnet groove.
6. Clean the grooves and/or seating area of the body and bonnet.
7. Apply a very thin film of clean grease to the bonnet seal ring and groove.
8. Install the new seal ring in the bonnet groove.
9. Install the bonnet over the body studs.
a. On valves 5000 psi WP and below, rotate the bonnet so that the bonnet
locating pins in the body align with the pin holes in the bonnet.
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b. On valves 10,000 psi WP and above, rotate the bonnet until the grease
fitting is 90° from the gate bore.
10. Thread the stem into the gate by turning the handwheel counterclockwise.
11. Pull the bonnet down over the studs.
12. Hand tighten the bonnet nuts.
13. Ensure that the gate is not on the bottom of the cavity.
14. Evenly tighten the bonnet nuts. (See Table IX.)
Note: The raised bonnet face on valves 10,000 psi and above will fully contact the body
face when the bonnet nuts are tight.
Table IX: Recommended Bonnet Stud Torque
Valve Size
113/16" 10,000
113/16" 15,000
21/16" 2000
21/16" 3000/5000
21/16" 10,000
21/16"15,000
29/16" 2000
29/16" 3000/5000
29/16" 10,000
29/16"15,000
31/8" 2000
31/8" 3000
31/8" 5000
31/16" 10,000
31/16" 15,000
41/16" 2000
41/16" 3000
41/16" 5000
41/16" 10,000
51/8" 5000
51/8" 10,000
61/8"/63/8" 2000
61/8"/63/8" 3000
61/8"/63/8" 5000
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Bonnet Stud Size - TPI
1.125-8
1.250-8
.625-11
.875-9
1.125-8
1.250-8
.750-10
1.000-8
1.250-8
1.500-8
.750-10
.875-9
1.125-8
1.250-8
1.500-8
.875-9
1.125-8
1.250-8
1.625-8
1.375-8
1.375-8
1.000-8
1.125-8
1.375-8
24
Recommended Stud Torque
ft-lb (N●m)
675(915)
950(1290)
115(160)
300(410)
675(915)
950(1290)
200(270)
475(645)
950(1290)
1675(2270)
200(270)
300(410)
675(915)
950(1290)
1675(2270)
300(410)
675(915)
950(1290)
2150(2915)
1275(1730)
1275(1730)
475(645)
675(915)
1275(1730)
VIII. ORDERING REPLACEMENT PARTS
The only information needed for ordering replacement parts for a Cameron gate valve
is the original valve assembly part number and the description of the part. The valve
assembly part number is stamped on the valve body nameplate. It is recommended
that a description of the valve assembly (size, pressure, trim) be included as a check
on the assembly number, but this is not necessary if the assembly number is clearly
readable.
It is not recommended to order replacement parts by using the part number off the
old part or by referring to a file copy of the valve assembly bill-of-material. If an
engineering change has been implemented to the valve assembly to replace one
component part number with another, the only way to ensure getting the updated
component is to reference the valve assembly number and to reference the part by
description (gate, seat, stem, etc. Part descriptions are shown in the parts list, Part
I.D.). Cameron personnel can then check the latest revision of the assembly
bill-of-material to obtain the appropriate and current replacement part number.
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