Operation and Maintenance Manual
Manually Actuated FL and FLS Gate Valves
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All the information in this manual is the exclusive property of Cooper Cameron Corporation, Cameron Division. Any reproduction or use of the calculations, drawings, photographs, procedures, or instructions, either expressed or implied, is forbidden without the expressed written permission of Cameron or its authorized agent.
Initial Release A1 April 1992 Revision B1 April 1994 Revision C1 June 1997 Revision D1 June 2005
Copyright © 2005 all rights reserved by Cooper Cameron Corporation, Cameron Division
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PREFACE The procedures included in this book are to be performed in conjunction with the requirements and recommendations outlined in API Specifica tions. Any repairs to the equipment covered by this book should be done by an authorized Cameron service representative. Cameron will not be responsible expense any of equipment any damagefor to loss any or property orresulting death orfrom injury to failure any person resulting or 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 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. This book covers Cameron products, which are products of Cooper Cameron Corporation. Cooper Cameron Corporation Cameron Division P.O. Box 1212 Houston, Texas 77251-1212 713-939-2211 http://www.coopercameron.com
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Table Of 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 . . . . . . . . . . . . . . . . . . 15 A. Valves 10,000 psi and Below . . . . . . . . . . . . . . . . . . . 15 B. Valves 15,000 psi 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 . . . . . . . . . . . . . 18 VI. Stem Packing Replacement With Pressure In The Valve . . . . . . . 19 A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . 19 B. Installation of the New Packing . . . . . . . . . . . . . . . . . 21 VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . 23 A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . 23 B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . 23 C. Gate and Seat Assembly . . . . . . . . . . . . . . . . . . . . . 24 VIII. Ordering Replacement Parts . . . . . . . .
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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 flange, threaded-end, and body configurations. The double following are standard features ofspecial the FL block 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 ass embly 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 dire ctions, and the gate and seats can be reversed for increased life. 4. The stem shoulder can be back seated against the bonnet to isol ate 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 lubricant 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 area 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.
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10. Special non-elastomeric stem packing designs can extend the standard temperature rating of the FL or FLS Gate Valve up to 350 o F (180oC), or down to -75 o F (-60oC). These temperature ratings may not be available in all working pressures. 11. An optional add-on torque multiplier is available for larger FL and FLS valves to provide easier operation. 12. of Seevalve the valve assembly bill-of materials for materials and descriptions 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 ¼ 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 (co unterclockwise) ½ to ¾ 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 2000-3000psiWP Valve Bore Size Inch
2-1/16
2-9/16
3-1/8
Expected Opening Torque, Lubricated Valve, ft-lb
15
20
25
Maximum Opening Torque, Severe Service, ft-lb
30
40
60
Total Number of Turns, Full-Open to Full-Close
12-1/3
15-1/8
18-1/8
4-1/16 30
5000psiWP
5-1/8 45
80
6-3/8 80
130
23-1/4
2-1/16 20
235
27-1/2
Expected Opening Torque, Lubricated Valve, ft-lb
1-13/16
2-1/16
2-9/16
30
35
50
65
80
85
130
170
12-1/3
12-1/3
15-1/8
18-1/8
3-1/8
35
50
25
45
65
33-3/4
12-1/3
10,000 psi WP Valve Bore Size - Inch
2-9/16
95
4-1/16 75
135
15-1/8
18-1/8
5-1/8
220
395
23-1/4
27-1/2
15,000 psi WP
3-1/16
4-1/16 110
5-1/8 260*
1-13/16 50
2-1/16
60
2-9/16
100
3-1/16
125
Maximum Opening Torque, ft-lb Severe Service, Total Number of Turns, Full-Open to Full-Close
320 23-1/4
690* 29
125 12-1/3
* Optional torque multiplier recommended. See manual #SD-1792.
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155
265
12-1/3
335 15-3/4
6-3/8
140
22-7/8
33-3/4
C. Dimensional Data
Table II: Dimensional Data - 2000 psi WP Ite m
D e s cri p ti o n
2 - 1/ 1 6”
A B
Extreme Width of Body
C
Center of Port to Top of Stem Adapter
6-1/8”
Center of Port to Bottom of Body
E
Center of Port to Top of Handwheel Rim
15-3/8” 14”
14” 160lb
22-3/4”
9-1/8”
19-1/16”
14”
12-3/8”
18-7/16”
7-1/8”
6”
22-1/8”
9-3/4”
16-13/16”
16-1/8”
6- 1 / 8 ”
17-1/8”
7-3/4”
33-13/16”
D
4 - 1/ 8 ”
14-1/8”
7-1/8” 13”
Weight(Flanged)
3 -1 /8 ”
13-1/8”
5-1/4”
F HandwheelOD
2- 9 / 1 6 ”
11-5/8”
End-to-End, Flanged (Ring Joint)
12-7/8”
20-11/16”
24” 18-1/2”
14”
200lb
240lb
350lb
800lb
Table III: Dimensional Data - 3000 psi WP It e m A A
D e s cr i p t i o n End-to-End,Threaded End-to-End, Flanged (Ring Joint)
B
xtreme Width of Body E
C
Center of Port to Top of Stem Adapter
D
Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim
E
F HandwheelOD Weight(Flanged)
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2 - 1/ 1 6” 10-5/8”
2 -9 /1 6 ”
12-3/8”
14-5/8"
16-5/8"
6-3/4”
7-5/8 ”
13” 5-5/8” 15-3/8” 14”
3 -1 / 8”
13-5/8”
20-1/8”
16-13/16” 7-3/8” 19-1/16” 14”
24-1/8”
24-1/8”
21”
18-7/16”
6 -1 / 8”
— 12-3/4”
21-5/16"
22-3/4”
9-1/8” 11-3/8” 12-7/8” 20-11/16” 22-9/16” 24”
18-1/2” 260lb
5 -1 /8 " —
10-1/2”
33-13/16”
220lb
9
17-1/8" 7-1/2”
6-1/2” 16-1/8” 14”
170lb
4- 1 / 8 ” —
450lb
24”
24” 750lb
1000lb
Table IV: Dimensi onal Data - 5000 psi WP Ite m A A A B
D e s c r ip t io n nd-to-End, E Threaded
2 - 1/ 1 6”
End-to-End, Flanged (Ring Joint) End-to-End,ButtWeld Extreme Width of Body
2 -9 /1 6 ”
10-5/8”
12-3/8”
14 -5/8"
3 -1 / 8”
16 -5/8"
—
—
18 -5/8”
— 7”
—
8-3/16”
21-5/8 ”
9-1/4”
D
5-5/8”
6-1/2”
7-3/8”
E
Center of Port to Top of Handwheel Rim
17-3/8”
18-1/8”
19-1/16”
F
HandwheelOD
14”
Weight(Flanged)
14” 175lb
16-13/16”
18-1/2” 230lb
28-5/8 ”
29”
— 21-3/4”
14-1/8”
18-7/16”
21-5/16"
9-1/8”
11-3/8”
20-11/16”
18-1/2”
360lb
6 - 1/ 8 ” —
—
10-13/16”
15-1/8”
15-15/16”
5 - 1/ 8 " —
21-1/2”
Center of Port to Top of Stem Adapter Center of Port to Bottom of Body
C
4 -1 / 8”
13-5/8”
12-7/8”
23-9/16”
24”
520lb
22-3/4”
24”
24”
800lb
1160lb
Table V: Dimensional Data - 10,000 psi WP It e m A B
D e s c r ip t io n
1 -1 3 /1 6 ”
End-to-End, Flanged (Ring Joint) Extreme Width of Body
C
Center of Port to Top of Stem Adapter
D
Center of Port to Bottom of Body
E
Center of Port to Top of Handwheel Rim
F HandwheelOD
2 - 9 /1 6 ”
20-1/2”
9-1/16”
9-3/8”
3- 1 / 1 6 ”
22-1/4”
4 -1 / 16 ”
24-3/8”
9-13/16”
5 - 1 /8 ”
26-3/8”
10-1/4”
29”
12-13/16”
23-1/2”
15-1/8”
15-1/8”
15-13/16”
16-7/8”
19-11/16”
23-7/8”
5-3/4”
5-7/8”
6-13/16”
8-1/16”
10-1/16”
13-1/8”
20-15/16”
25-1/4”
17-3/8” 14”
Weight(Flanged)
2 -1 /1 6 ”
18-1/4”
17-3/8”
18-1/2” 250lb
18-1/8”
18-1/2”
275lb
18-1/16” 24”
370lb
24”
480lb
24”
880lb
1750lb
Table VI: Dimensional Data - 15,000 psi WP Ite m A B
D e s c r ip t io n End-to-End, Flanged (Ring Joint) ExtremeWidthofBody
1 - 13 / 16 ” 18”
2 - 1/ 16 ” 19”
9-7/8”
2 -9 /1 6 ”
9-7/8”
23-9/16” 11-1/2”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-1/8”
17-3/16”
D
Center of Port to Bottom of Body
5-7/8”
6-1/8”
7-5/16”
E
Center of Port to Top of Handwheel Rim
F HandwheelOD Weight
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17-3/8” 18-1/2”
17-3/8” 18-1/2”
275lb
10
3 - 1/ 1 6”
21”
300lb
13-9/16” 20-15/16” 9-1/4”
19-9/16”
22-3/16”
18-1/2”
24”
560lb
890lb
D. Parts List
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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 (-29oC to 121 oC). 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 (-29oC to 121 oC). 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.)
Lubricant Volume
Pressure Rating
1-13/16"
All
38
1.5
2-1/16”
All
43
1.7
2-9/16" To 10,000
79
2-9/16" 15,000
93
3-1/8”
To 5000
3-1/16” 10,000 15,000
4-1/8”
To 5000
4-1/16” 10,000
Approximate Follower
(lb)
Plate Travel (in.)
.5 .7 3.2
3.7
114
4.6
114
3-1/16”
Lubricant Weight
Required (cu in.)
155 245 243
1.3 1.6 1.9
4.6
1.9
6.2
2.6
9.8
4.2
9.7
4.1
5-1/8”
5000
312
12.5
5.3
5-1/8” 6-1/8”
10,000 To 5000
461 583
18.5 23.3
7.8 9.9
6-3/8”
To 5000
583
23.3
9.9
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Table VIII: Lubricant Selection Lubricant
Service
Op er ationa l Prop er ties
Name
o
o
e d u r C d r a d n ta S Standard
CI-14 or TF-41
Arctic
NS-14
Diesel Resistant
SS-14 or TS-41
High Temp High Temp
l e s e i D
E
E P
P E
G P
F - Fair P - Poor
P
P P
G F P E
Moly101
E - Excellent G - Good
0 5 6 + to T R . p m e T h g i H
s e t a s n e d n o C ll e
2
O C h ig H ry e V
W s a G th i W
E P P PFFP E
HT-14S
F 5 7 o t . p m e T w o L
) s a G r o e d ru C r u o S ( S 2 H tih W
F
G F
E
F
G
F F
F
G
G
Quantities (By Part Number) Available on a Standard Order Basis
Solven t
P
) d n u o P r e P (
m ru D . lb 0 2 1
li a P . lb 5 2
n a C . lb 5
m ru D . lb 0 0 4
Mineral Spirits
700149
700667
700668
700669
700670
Mineral Spirits
700123
700671
700672
700673
700674
Alcohol
700150
700675
700676
700667
700678
P
Mineral Spirits
700217
700679
700680
700681
700682
P
Mineral Spirits
710194
700679
700680
700681
700682
Example For Ordering: Order Part Number 700672 for 25 lb. of NS-14
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.
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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. 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. Fluid leaks around the valve stem.
Cause
Action
1. Gate or seats are worn. 2. Handwheel is not backed off. Stem packing is worn.
Fluid leaks at the bonnet flange.
1. Bonnet seal ring is worn. 2. Bonnet or body ring groove oois damaged.
Fluid leaks from the bonnet grease fitting.
Check valve inside the grease fitting is worn. 1. Thrust bearings have lost oolubricant.
Handwheel is hard to turn.
Handwheel turns without opening or closing the valve.
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2. Thrust bearings are corroded.
Replace the gate or seats. Back off the handwheel ¼ turn. Replace the stem packing. Replace the bonnet seal ring. Return the valve to Cameron for repair. Replace the grease fitting. Lubricate the thrust bearings. Replace the thrust bearings.
3. Gatelubricant. and stem threads have oolost
through the Lubricate thebonnet gate and grease stem fitting.
Stem shear pin is sheared.
Replace the stem shear pin.
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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. 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. b. Trip the ball in the grease fitting check valve by inserting a 1/8” diameter by ¾” 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. 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. TC148
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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 (33 N•m). 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 (270 N•m).
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. 1. Backseat the valve. 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 4. TC148
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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. 4. Remove the cap from a new grease fitt ing and install the fitting in the bonnet. Torque to 80 to 100 ft-lb (10 0 to 135 N•m). 5. Install and tighten the cap on the fit ting. Caution:
Installing the fitting with the cap in place prevents the fitting from seating and could caus e 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 (33 N•m). 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 (270 N•m).
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.
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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 contac t a Cameron representative. 2. If the bearing cap rotates freely, remove the cap from the bonnet. 3. Using a punch, dri ve the stem shear pin from the stem adapte r, ensuring that the adapter is not damaged. 4. Remove the adapter from the stem. Remove both sets of bearings and bearing races from the stem adapter. 5. Discard any pitted, cracked, or damaged bearings or races. 6. Replace the stem adapter if either of the bearing surf aces on the adapter shoulder is damaged.
B. Installation of the New Thrust Bearings. 1. Remove the new bearings from the protective packaging. 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 bearin gs and races over the bottom of the adapte r 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 ste m and align the pin hole in the adapter with the hole in the stem. 7. Using a punch, drive in the ste m pin and ensure th at 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 extr a race, held by grease tension, is not retained inside. TC148
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10. Clean the bearing cap and lubr icate the threads. 11. Install the cap, and tighten to approximately 200 ft-lb (270 N•m). 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. grease Inject grease cap grease fittings until the excess passesthrough throughthe thebearing bleed port.
VI. Stem Packing Replacement with Pressure in the Valve
A. Removal of the Stem Packing 1. Backseat the valve. 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. Backseat the valve. 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 ¾” 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 b 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 in ineffective. a) Backseat the valve again. Repeat steps 1 and 2.
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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 in 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. 5. Using a punch, dri ve the stem shear pin from the stem adapte r, ensuring that the adapter is not damaged. 6. Remove the adapter from the stem. 7. Remove both sets of bearin gs and bearing races from the ste m adapter. 8. Loosen the packing gland. 9. Ensure that the threads on the bonnet neck OD are not damag ed. 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 1 ¼” 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.
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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.
Caution:
2) Pull the packing out with a corkscrew. 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 hydraul ic lock will not prevent the installation of new packing. 2. Inspect the stuffing box to ensure that the bore is cle an and free of pits or scars. 3. Inspect the stem to ensur e 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. 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 or SLS 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 packi ng 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.
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8. Install the packing gland and apply approximately 200 ft-lb (270 N•m) of torque, ensuring that the bonnet threads are not damaged. 9. Inspect the bearings and bearing race s 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 bearin gs and races over the bottom of the adapte r 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 alig n the pinhole in the adapter with the hole in the stem. 15. Using a punch, drive in the ste m pin and ensure th at 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 extr a race, held by grease tension is not retained inside. 18. Clean the bearing cap and lubr icate the threads. 19. Install the cap, and torq ue to 200 ft-lb (270 N•m ). 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.
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VII. Gate and Seat Replacement
A. Gate and Seat Disassembly 1. Isolate the valve from the line press ure. 2. Release the cavity pressure by bleeding the cavity pressure through the bonnet grease fitting. 3. With the bonnet grea se fitting still vented, stroke the valv e one complete cycle, ending in the full open position. Caution:
Any trapped pressure will be vented through the bonnet grease fitting or end flange. 4. Remove all bonnet nuts. 5. Support the bonnet and turn the handw heel 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 seat and pry the seat out. 9. Flush the body cavity thoroughly with 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.
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.
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3. Ensure that the body cavi ty is free of all foreig n matter such as solid particles, grit, trash, etc. 4. Clean the body cavity wit h a suitable cleaning solvent. 5. Apply a thin coat of clea n grease to the body cavi ty, 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 bot tom 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 clea n grease to the bon net seal ring and groove. 8. Install the new seal ring in the bonne t 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 pinholes in the bonnet. 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 turni ng the handwheel counterclockwise.
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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 cav ity. 14. Evenly tighten the bonnet nuts. (See Table Below.) Note:
The raised bonnet face on valves 10,000 psi and above will fully contact the body face when the bonnet nuts are tight. Recommended Makeup Torques, Ft-Lbf Per API 6A: Preload = .50Sy English Units B7M, L7M (80 ksi)
Bolt Size Nom OD - TPI
Xylan or Sermagard Coated
Zinc Plated or Uncoated
B7, L7, 660 (105 ksi) Xylan or Sermagard Coated
Zinc Plated or Uncoated
.625-11
52
88
68
.750-10
90
153
118
115 200
.875-9
143
243
188
319
1.000-8
213
361
279
474
1.125-8
305
523
401
686
1.250-8
421
726
553
953
1.375-8
563
976
739
1280
1.500-8
733
1280
962
1680
1.625-8
934
1640
1230
2150
Recommended Makeup Torques, N•m Per API 6A: Preload = .50Sy Metric Units B7M, L7M (80 ksi) Bolt Size Nom OD - TPI
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Xylan or Sermagard Coated
Zinc Plated or Uncoated
B7, L7, 660 (105 ksi) Xylan or Sermagard Coated
Zinc Plated or Uncoated
.625-11
70
118
92
.750-10
122
206
160
270
.875-9
193
328
253
429
1.000-8
288
488
376
639
1.125-8
413
706
540
925
1.250-8
569
981
745
1290
1.375-8
761
1320
996
1730
1.500-8
991
1730
1300
2270
1.625-8
1260
2210
1660
2910
25
155
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VIII. Ordering Replacement Parts The only information needed for ordering replacement parts for a Cameron gate valve is the srcinal valve assembly part number and the description of the part. The valve assembly part number is stampe d 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 descrip-
tions 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. The replacement parts list included in this manual contain part numbers for Cameron FL manual and surface actuated failsafe gate valves manufactured prior to API 6A 15th Edition (1986), operating in the temperature ranges between -20 and 250oF (-29 and 121 o C). Contact your Cameron representative for replacement parts for FLS and all other FL gate valves.
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Figure 1 FL MANUAL GATE VALVE ALL EXCEPT 3-1/16 15,000 PSI WP
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FIGURE 2 FL MANUAL GATE VALVE 3-1/16 15,000 PSI WP
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FIGURE 3 FL GATE VALVE PREPPED FOR ACTUATOR ALL SIZES AND PRESSURES
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