5-WKM Valves Cameron

Repair Manual for WKM Model M Gate Valve

RP971837

WKM Model M Repair Procedure Covering 2-1/16", 2-9/16" & 3-1/8" 2,000, 3,000 & 5,000 psi Working Pressure Gate Valves

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December 1997 Page 21

Table of Contents Bill of Materials ....................................................................................................... 1 Stage 1

Stage 2 Stage 3

Stage 4 Stage 5 Stage 6

Disassemble the Valve ................................................................. 2

Recommended Tools ....................................................................................................................... 2 Isolate the Valve from Pressure ....................................................................................................... 2 Venting Trapped Pressure ............................................................................................................... 2 Removing the Bonnet and Gate Assemblies ................................................................................... 2 Removing Internal and external Body Components ......................................................................... 3 Disassasemble the Bonnet .............................................................................................................. 4

Clean and Inspect All Components ............................................. 5 Reassemble the Valve .................................................................. 7

Recommended Tools ....................................................................................................................... 7 Install the New Seats ....................................................................................................................... 7 Install the Gate Guides .................................................................................................................... 8 Install the Gate Assembly ................................................................................................................ 9 Reassemble the Bonnet ................................................................................................................. 10 Install the Bonnet Assembly ........................................................................................................... 12

Drift the Valve .............................................................................. 14 Test the Valve .............................................................................. 15

Hydrostatic Body Teat .................................................................................................................... 15 Hydrostatic Seat Test ..................................................................................................................... 15

Grease the Valve ......................................................................... 16 Lubricant Selection Chart .......................................................... 17 Amount of Lubricant Required .................................................. 17


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Bill of Materials Handwheel Nut Handwheel Bearing Retainer Locknut Bearing Retainer Bearing

Stem

Bearing Bearing Sleeve Packing Retainer Packing Set Bearing Grease Fitting Plastic Injection Fitting

Bonnet Nut

Bonnet Seat Gate Guide Gate Assembly Bonnet Seal Ring

Bonnet Stud

Body Body Lubrication Fittings RP971899

This manual details repair procedures for repair of the valve by replacement of components. To perform these repairs the valve must not be under pressure and any pressure trapped within the valve body cavity must be released. For the purpose of this manual, the valve will be treated as if it has been removed from the line and is out of service.


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Disassemble the Valve Recommended Tools

Hammer Wrench 7/8" Wrench Slip Type Seat Removal Tool/ Drive Bar Bearing Retainer Removal/Installation Tool Rubber Mallet Sledge Hammer Pry Bar Packing Fitting

Always ensure the equipment to be repaired is isolated from all pressure. Also that any trapped pressure has been bled off prior to disassembling.

Isolate the Valve from pressure 1. 2.

Bonnet

Close off downstream equipment and bleed off all pressure through upstream equipment. Close off upstream equipment and monitor open needle valve or pressure gauge to ensure valve has been isolated from pressure.

Gate Segment (Pressure Side)

Venting Trapped Pressure 3.

4. 5.

Once the valve has been isolated from all pressure or removed from line, cycle the valve at least one time to release any trapped pressure inside the valve body. In the event the valve will not operate use a bleeder tool and attach it to one of the two body grease fittings. Carefully vent the pressure by turning the T handle on the bleeder tool to the right until it offsets the ball check.

Bonnet Seal Ring Gate Guide

Removing the Bonnet and Gate Assemblies 6.

7. 8.

Once all pressure has been vented from the valve body and the valve has been either isolated from pressure or removed from the line, remove the Packing Injection Fitting using a 7/8" wrench. Remove the nuts from the bonnet bolts using an appropriately sized hammer wrench. Remove both the bonnet and gate assemblies from the valve body and set aside.

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Seat

Direction of Flow (Pressure Side)

RP971840

Disassemble the Valve Removing Internal and External Body Components

Remove both Body Lubrication Fittings. 10. Remove the Bonnet Seal Ring taking care not to damage the gasket seal area in the valve body. 11. Remove the gate guides from the seats by first dislodging the ring from the top of the seat and then by unhooking the gate guide from under the bottom of the seat. Remove the gate guides from the valve body. NOTE: In step 11 it may be beneficial to turn the valve up on one outlet and then the other to remove the seats. 12. With one hand insert the seat removal slips into the top outlet, big end first. 13. Insert the other hand into the valve body cavity and position it directly below the outlet. 14. Drop the Seat removal slips into the outlet and catch them with the free hand 15. Adjust the slips so that they will bite thwe bore of the seat and will not bite the bore of the valve. Improper positioning may result in severe damage to the seat pocket.

Extracting A Seat

9.

Drive Bar Slips

RP971839

16. Insert a bar into the exposed outlet and land it between the two slip halves, remove the free hand from the valve body cavity. 17. Using a sledge hammer firmly strike the bar thus driving the seat out of the pocket. WARNING: Do not strike the flange face as this may cause damage to the ring groove.


18. Remove the old seat and seat removal tool from the body cavity and inspect the tool for damage. 19. Flip the valve body over onto the other outlet and repeat steps 10 through 16 on the opposite seat. NOTE: Seats will not always knock out on the first try and the process of removing the seats may need to be repeated a few times.

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Disassemble the Valve Disassemble the Bonnet 20. Remove the gate assembly from the stem using right hand rotation. 21. Remove the Handwheel. 22. Using the Bearing Removal/Installation Tool, remove the bearing retainer locknut and bearing retainer with left hand rotation. 23. Remove the stem from the bonnet by pulling it straight out of the top of the bonnet. NOTE: In most cases when the stem is removed both of the bearings, bearing sleeve, packing retainer and top three pieces of packing will remain attached and come out with it. 24. Remove all internal components of the bonnet including two bearings, bearing spacer, packing retainer, one set of chevron packing, and teflon impregnated plastic packing. 25. Remove the bearing grease fitting with right hand rotation.

Handwheel Nut

Handwheel Bearing Retainer Locknut Bearing Retainer Bearing Sleeve

Bonnet Assembly

Upper Bearing

Bearing Flange

Stem

Bearing Retainer/ Removal Tool

Bulk Packing Separates Upper and Lower Packing Rings

1-1/4" Hex

Lower Bearing Packing Retainer

Bonnet Seal Area

Open lips of Packing Rings Face Pressure

Upper Packing Rings Lower Packing Rings

Stem Recess

Bearing Grease Fitting

Bonnet RP971844

RP971842

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Clean and Inspect The inspection process is criticle in determining the repairability of the valve before any replacement parts are installed.It is also important in determining wether the valve body and bonnet are capable of withstanding test pressures. In determining these factors always use the guidelines set forth by the Cameron quality department.

Handwheel Nut Threads

1.

Thoroughly clean the entire valve body, bonnet and all internal components, removing any grease or other debris from all pieces 2. Hand clean the seat pockets of the valve body and packing box of the bonnet using a degreaser or other approved cleaning agent. 3. Inspect the seat pockets of the body and bonnet seal ring area of the body and bonnet for any damage. 4. Gauge all threads of the bonnet and body. NOTE: WKM valves are serialized with a 7 digit number and what is refered to as a 'Dash Number' which indicates seat size. Due to the fact that these valves may have been previously repaired or machined it is necessary to include Step 5. 5. Measurethe seat pocket of the valve body to verify the size of the seat that is called out in the serial number. 6. Inspect the stem for signs of damage to the gate threads or packing seal area.

Bearing Flange

Packing Area

Seat

Operating Threads

Dia.

RP971860

Teflon Insert RP971845


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Clean and Inspect 7.

Inspect bearings for signs of corrosion and for free movement. 8. Inspect the packing retainer for any damage. 9. Inspect the bearing retainer and bearing retainer locknut for signs of damage to threads or ID finish. 10. Inspect gate for signs of damage to either face or internal stem threads. 11. Inspect gate guides for corrosion or if they may be bent. 12. Measure flange conections to API standards. 13. Replace parts as necessary. NOTE: It is not necessary to inspect the seats as they are damaged when removed.

Stem Threads

Gate Spring

Pressure Side

Tab

Gate Segments RP971861

RP971862

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Reassemble the Valve Recommended Tools

Hammerwrench 7/8" wrench Press Plate Drive Bar Rubber Mallet

Install the New Seats 1. 2. 3. 4.

Place the valve body in the seat press. Turn the valve up on the outlet. Ensure the seat pocket is clean and free of any debris. Examine the Seat to be installed in the seat pocket. Verify the following. seat is correct size for the valve in which it will be used teflon insert is properly installed and undamaged OD is free of burrs that may cause damage to valve 5. Lightly grease the OD of the seat to be installed. 6. Orient the seat with the teflon insert facing up. 7. Place the seat in the seat pocket until it stops, ensuring it is level. NOTE: The seat will only fit into the pocket slightly because of the press fit tolerance between the seat and the body. 8. Examine the Press Plate. Verify the following face of the plate is clean and free of any foreign matter alignment hole is clean and free of debris 9. Orient the Press Plate with the alignment hole facing up. 10. Insert the press plate into the valve body cavity and center it on the seat. 11. Examine the Drive Bar. Verify the pin is intact and secure. 12. Orient the Drive Bar with the pin end down. 13. Insert the Drive bar into the exposed outlet and into the Press Plate.

RP971863

Drive Bar

Press Plate

RP971864


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Reassemble the Valve 14. Ensure the pin is inserted into the alignment hole of the Press Plate. 15. Gently tap the end of the bar to start the seat into the seat pocket, then check to ensure the seat is still level in the pocket. If the seat becomes tilted in the seat pocket remove the bar and gently tap the high side of the press Plate until the seat levels up. 16. Using the Seat press apply up to 5,000 psi to install the seat into the seat pocket. Hold the pressure approximately one minute and release pressure. NOTE: Wile the valve is held firmly in place, install the body lubrication fittings into the 1/2" npt ports on the front of the valve body. 17. Remove the bar and press plate andverify that the seat is level, ensure the teflon insert is undamaged. 18. Flip valve onto opposite outlet and repeat process for other seat.

Install the Gate Guides

19. Remove the valve from the seat press and set the valve upright. 20. Examine the Gate Guides. Verify the following: guides are proper size are not bent or otherwise disfigured 21. Orient the gate guide with the edges facing away from the seat pocket. 22. Insert the gate Guide into the body cavity and hook the tongue under the bottom side of the seat. 23. Fit the top of the gate guide seat opening over the top of the seat until it fits snugly and the face of the guide is flush with the face of the seat. 24. Repeat this process for the other gate guide on the opposite seat.

RP971846

Seat Tounge Gate Guide

RP971847

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Reassemble the Valve Install the Gate Assembly 25. Examine the Gate Assembly. Verify the following: Internal stem threads are clean, free of debris and undamaged bore is clean and free of debris both faces are free of any mars or pits that may prevent sealing 26. Unless the valve body is otherwise marked, orient the pressure side face of the gate to be installed to face the right side of the valve. 27. Grease both faces of the gate with a light oil or grease to aid in the installation. 28. Carefully slide the gate in between the Gate Guides and seats into position with the bore of the gate approximately even with the bore of the valve. NOTE: Sometimes the gate may fit rather tight, in these events it may become necessary to use a rubber mallet to force the gate into position. WARNING: Do Not marr the face of the gate or the seat during this operation or the assembly may not seal.

RP971865


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Reassemble the Valve Reassemble the Bonnet

29. Examine the bonnet. Verify the following: bore is clean and free of debris threads are clean and undamaged packing box is clean with no marrs or pitting seal ring area is clean and in good condition with no pits or marrs 30. Orient the bonnet with the flange down. 31. Prepack both the bonnet bearings with a lightweight lithium based grease prior to installation. 32. Slide one bearing onto the stem, over the operating threads, until the race comes in contact with the bearing flange. 33. Install the packing retainer in the same manner until the flat bottom contacts the bearing. 34. There are six pieces of chevron packing in a set of a model M valve. They are a bottom male piece four Vee packing and a top female piece. 35. Split the packing in half with the male piece and two Vee packing in the bottom half and the female piece and two Vee packing in the top half. 36. Slide the top half of the packing set onto the stem with the flat surface of the female piece against the packing retainer and the two vee packing pieces cupped against the female piece. NOTE: Do Not attempt to thread the chevron packing onto the stem, this will only damage the ID of the packing.

Bearing Retainer Threads

Handwheel Nut

Handwheel Bearing Retainer Locknut Bearing Retainer Bearing Sleeve

Upper Bearing Bearing Flange

Lower Bearing

Packing Retainer

Packing

Stem

Bonnet Packing

Bearing Grease Fitting Packing Box

Plastic Injection Fitting Port

Bonnet Seal Area

RP971866

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RP971843

Reassemble the Valve 37. Install the bottom half into the bonnet with the flat side of the male piece against the bottom of the packing box and the two Vee pieces cupping it. 38. Wrap the stem just below the chevron packing with teflon impregnated strip packing. NOTE: Do Not let the Strip of packing overlap the chevron packing or be larger than the OD of the packing. 39. Install the other bearing over the other end of the stem until the race contacts the bearing flange. 40. Slide the Bearing Sleeve over the two bearings, it will land on the bottom of the packing retainer. 41. Insert the stem into the bonnet, operating threads first, passing it through the chevron packing in the bottom of the bonnet packing box. 42. Using a rubber mallet lightly tap the stem until it seats fully into the bonnet. 43. Install the bearing retainer into the bonnet and tighten fully. NOTE: The bearing Retainer will countersink into the bonnet approximately 3/16". 44. Install the bearing retainer locknut over the bearing retainer and tighten to refusal. NOTE: The bearing retainer locknut should be close to flush with the top of the bonnet body. 45. Install the bearing grease fitting.

Bonnet Assembly

Bulk Packing Separates Upper and Lower Packing Rings

Bonnet Seal Area


Open lips of Packing Rings Face Pressure

RP971867

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Reassemble the Valve Install the Bonnet Assembly

46. Thoroughly grease either the internal threads of the Gate Assembly or the operating threads of the stem. 47. Install the Bonnet Seal Ring onto the seal shoulder of the valve body. NOTE: Since this is a deformation seal it may be necessary to tap the Bonnet Seal Ring into position with a rubber mallet. 48. Orient the bonnet assembly with the flange down. 49. Ensure the seal area of the bonnet is clean. 50. Insert the operating threads of the stem into the threads of the gate and using left handed rotation make up the connection fully. 51. Orient the packing fitting port and allemite fitting to the front of the valve. 52. Install the bonnet nuts onto the studs hand tight only. 53. Fully open the valve to prevent the gate from bottoming out on the body during the tightening of the bonnet. 54. Tighten the bonnet bolts in an alternating cross pattern until the bonnet and body come face to face.

Bonnet Seal Ring

RP971868

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Reassemble the Valve 55. Install plastic injection fitting into it's respective port and tighten. 56. Energize the bonnet packing by removing the packing plunger, inserting a small amount of plastic packing and reinserting the plunger. Continue this process until the handwheel operates at a comfortable amount of friction but not too tight.

Packing Plunger

RP971869


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Drift the Valve Drift the Valve The drift of all gate valves is essential, especially in the run of a Christmas tree assembly to ensure that all future downhole equipment is able to pass through the bore of the tree. 1. Fully open the Gate valve. 2. Visually inspect the bore to ensure the gate and seats are properly aligned. NOTE: If the gate and seats are not properly aligned it may be necessary to 'Jam' the valve shut very tightly or back off the gate 1/4 to 1/2 turn to let the bore line up. 3. Select the appropriately sized drift by referring to the latest API 6A manual. 4. Drift in accordance with the above referenced API manual. NOTE: Drift all valves in both directions to ensure full compliance and product quality.

Drift Bar

RP971870

Drift Bar

RP971871

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Test the Valve During the testing of any equipment, it is of the utmost importance to use any and all safety precautions available. All gate valve testing shall be done in accordance with the latest API 6A manual.

Hydrostatic Body Test 1.

Secure the valve to avoid any unnecessary movement during the test procedure. 2. Attach the appropriate test apparatus to the outlets of the valve and tighten fully. NOTE: Always apply test pressure from the pressure side of the valve. 3. Open the valve approximately half way. This will allow the valve body to fill completely with water for the body test. 4. Attach the test pump to the pressure side of the valve. 5. Slowly apply pressure to the API specifications found in table 7.9 on page 7-16 of the above referenced manual. 6. Follow generally accepted test inspection practices when searching for possible sources of leaks. 7. If a leak occurs, carefully bleed all pressure of valve and test equipment. 8. Cycle valve fully open then fully closed to ensure there is no trapped pressure in the body. 9. Repair as necessary. 10. Retest in accordance with API.

To Test Pump

RP971872

To Test Pump

Hydrostatic Seat Test

11. Once a satisfactory series of body tests are completed and all test pressure has been bled off the valve and test equipment, remove the test apparatus from the nonpressure side of the valve. 12. Close valve completely and 'jam' shut. 13. Thoroughly clean the exposed face of the valve gate, removing any residual grease and water. 14. Slowly apply test pressure to opposite side of valve in accordance with the above specified API manual. 15. Using generally accepted test practices verify that there is no water leakage past the gate or from between the seat and valve body. 16. If a leak is observed, carefully bleed off test pressure from both valve and test equipment. 17. Cycle valve fully open to ensure any trapped test pressure is completely bled off. 18. Repair as required. 19. Retest in accordance with API.


RP971873

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Grease the Valve 1.

Once a satisfactory test has been achieved and all test pressure is completely bled off, locate the two body grease fittings on the front of the valve body, 2. Remove the dust cap from each fitting. 3. Attach a bleeder tool to either of the fittings and open tool. 4. Attach the greasing apparatus to the other fitting. 5. Fully open or fully close the valve to prevent grease from bleeding into the bore before fully filling valve body. 6. Inject the grease into the valve body until a constant stream flows from the bleeder tool. Refer to the charts on page 18 for the type and amount of grease to inject. 7. Stop injecting grease while leaving bleeder tool open to prevent any pressure from building inside valve body. 8. Remove grease injecting apparatus. 9. Remove bleeder tool. 10. Clean any excess grease from valve body and fittings. 11. Reinstall dust caps to body grease fittings. 12. Open valve fully. NOTE: The valve is opened after greasing to prevent any possible damage to gate faces during storage.

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Attach Bleeder Tool

Remove Dust Cap and Inject Grease

Lubricant Selection

P

P

P

F

F

P

Mineral Spirts

700149 700667 770668 770669 770670

Artic

NS-14

E

E

P

P

F

F

P

Mineral Spirts

700123 770671 770672 770673 770674

Standard

SS-14 or TS-41

E

P

E

P

G

G G

Alcohol

700150 700675 770676 770677 770678

Standard

HT-14

G

F

P

E

F

F P

Mineral Spirts

700217 700679 770680 770681 770682

Standard

Moly 101

G

P

P

E

G

F P

Mineral Spirts

700194 700679 770680 770681 770682

E=Excellent

F=Fair

G=Good

P=Poor

25 lb Pail

400 lb Drum

E

125 lb Drum

Very High CO2

CI-14 or TF-41

5 lb Can

With Gas Well Condensates

Standard

(per pound)

With H2S (Sour Crude or Gas)

QUANTITIES (by part number) Available on a standard order basis

High Temp RT to +650° F

SOLVENT

Diesel

OPERATIONAL PROPERTIES

Low Temp to -75° F

LUBRICANT NAME

Standard Crude

SERVICE

Example for Ordering: Order Part Number 700672 for 25 lb Pail of NS-14

Amount of Lubricant Required Bore Size

Pressure rating

(inches)

(psi)

Lubricant Volume Required (cubic inches)

Lubricant Weight

Approximate Follwer Plate Travel

(pounds)

(inches)

2-1/16

to 5000

43

1.7

.7

2-9/16

to 5000

79

3.2

1.3

3-1/8

to 5000

114

4.6

1.9

4-1/8

to 5000

245

9.8

4.2

5-1\8

to 5000

312

12.5

5.3

6-1/8

to 5000

583

23.3

9.9

6-3/8

to 5000

583

23.3

9.9


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5-WKM Valves Cameron

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