Operation and Maintenance Manual
Manually Actuated FLS-TC Fire Resistant Gate Valves with Heat Sensitive Backseating Feature
TC1354
All the information contained 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 written permission of Cameron or its authorized agent.
Initial Release A1 November 1998
Copyright © 1998 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 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 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 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 a Cameron gate valve, which is a product 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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Contents I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Description and Features . . . . . . . . . . . . . . . . . . . . . . . . 7 B. Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 8 C. Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 D. Assembly Drawings and Parts Lists . . . . . . . . . . . . . . . . . . . 14 II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 A. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 B. Body Cavity Lubrication . . . . . . . . . . . . . . . . . . . . . . . . 21 C. Thrust Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . 22 III. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 IV. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . 23 V. Stem Shear Pin Replacement . . . . . . . . . . . . . . . . . . . . . . . . 24 VI. Backseat Seal Engagement . . . . . . . . . . . . . . . . . . . . . . . . . 25 VII. Backseat Seal Verification . . . . . . . . . . . . . . . . . . . . . . . . . 27 A. For Valves Rated 10,000 psi and Below . . . . . . . . . . . . . . . . 27 B. For Valves Rated 15,000 psi and Above . . . . . . . . . . . . . . . . 28 C. For Valves with Special “Buried” Check Valve Below Grease Fitting. 29 VIII. Backseat Seal Disengagement And Bearing Mount Adjustment. . . . . 30 IX. Bonnet Grease Fitting Replacement . . . . . . . . . . . . . . . . . . . . 33 A. For Valves Rated 10,000 psi and Below . . . . . . . . . . . . . . . . 33 B. For Valves Rated 15,000 psi and Above . . . . . . . . . . . . . . . . 33 X. Thrust Bearing Replacement And Fusible Ring Inspection . . . . . . . . 34 A. For Conventional Threaded Bearing Cap Designs . . . . . . . . . . . 34 B. For Designs with Bearing Cap Retained by Threaded Ring . . . . . . 36
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XI. Stem Seal Replacement With Pressure In The Valve . . . . . . . . . . . 39 A. Stem Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 B. Stem Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40 XII. Gate And Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . 41 A. Gate and Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . 41 B. Parts Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . 44 C. Gate and Seat Installation . . . . . . . . . . . . . . . . . . . . . . . 45
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I. GENERAL INFORMATION A. Description and Features The FLS-TC gate valve is a forged, full-bore, through-conduit valve available in standard double flange and special block body configurations. The following are features of the FLS-TC gate valve: 1. Bi-directional design provides flow direction versatility and increased service life. 2. Positive metal-to-metal sealing (gate-to-seat and seat-to-body). 3. Simple, reliable gate and seat design promotes ease of field service and minimal spare parts inventory. 4. Two spring-loaded, pressure energized, non-elastomeric lip-seals between each seat and body assist in low pressure sealing. They also protect against intrusion of particle contaminants into the body cavity and seal areas. 5. Stem seal design covers full range of pressures, temperatures, and fluids encountered in wellhead and manifold service. 6. Metal-to-metal bonnet seal, (pressure energized 10,000 psi WP and above). 7. Stem can be backseated to allow stem seal replacement with the valve under pressure. 8. Grease injection fitting located downstream of stem backseat for safety. Fitting located in bonnet, eliminating body penetration. 9. Bearing cap grease fitting allows positive bearing lubrication. 10. An optional add-on torque multiplier is available to provide easier operation. 11. Bearing Cap incorporates a eutectic ring which, upon melting in a fire, allows the stem to automatically move to the backseat sealing position against the bonnet. a. Stem cross-sectional area is sized to provide adequate force from valve pressure to backseat the stem, overcoming gate drag friction. b. Springs within the bearing cap move the stem to the backseat position in the event there is minimal pressure in the valve.
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12. See the valve assembly bill of material for component part numbers and description. B. Operating 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 (when the top of the gate contacts the bonnet). Then turn the handwheel back to the right ¼ turn to relieve any stress in the stem. Initial torque required to open the valve is shown in Table I. The valve is closed by turning the handwheel clockwise (to the right) until it stops and then backing off (counterclockwise) ½ to ¾ turn. The number of turns required to move the valve from full open to full closed is shown in Table II. Table I: Operating Torque Requirements - English Units 2000 - 3000 psi WP Valve Bore Size
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8”
6-1/8”
6-3/8”
7-1/16”
Expected Opeing Torque, Lubricated Valve, (ft-lb)
15
20
25
30
45
70
80
110
Maximum Opening Torque, Severe Service, (ft-lb)
30
40
60
80
130
210
235
310
5000 psi WP Valve Bore Size
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8”
6-1/8”
6-3/8”
7-1/16”
9”
Expected Opeing Torque, Lubricated Valve, (ft-lb)
20
25
35
50
75
210
140
233
470
Maximum Opening Torque, Severe Service, (ft-lb)
45
65
95
135
220
350
395
520
850
10,000 psi WP Valve Bore Size
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
5-1/8”
6-3/8”
Expected Opeing Torque, Lubricated Valve, (ft-lb)
30
35
50
65
110
260
520
Maximum Opening Torque, Severe Service, (ft-lb)
80
85
130
170
320
690
1040
15,000 psi WP Valve Bore Size
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
Expected Opeing Torque, Lubricated Valve, (ft-lb)
50
60
100
125
275
Maximum Opening Torque, Severe Service, (ft-lb)
125
155
265
335
690
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Table I: Operating Torque Requirements - Metric Units 2000 - 3000 psi WP Valve Bore Size
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8”
6-1/8”
6-3/8”
7-1/16”
Expected Opeing Torque, Lubricated Valve, (N•m)
20
27
34
41
61
95
108
149
Maximum Opening Torque, Severe Service, (N•m)
41
54
81
108
176
285
319
420
5000 psi WP Valve Bore Size
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8”
6-1/8”
6-3/8”
7-1/16”
9”
Expected Opeing Torque, Lubricated Valve, (N•m)
27
34
47
68
102
285
190
316
637
Maximum Opening Torque, Severe Service, (N•m)
61
88
129
183
298
475
536
705
1152
10,000 psi WP Valve Bore Size
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
5-1/8”
6-3/8”
Expected Opeing Torque, Lubricated Valve, (N•m)
41
47
68
88
149
353
705
Maximum Opening Torque, Severe Service, (N•m)
108
115
176
230
434
936
1410
15,000 psi WP Valve Bore Size
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
Expected Opeing Torque, Lubricated Valve, (N•m)
68
81
136
169
373
Maximum Opening Torque, Severe Service, (N•m)
169
210
359
454
936
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C. Dimensional Data
F 3.75" (95.25 mm)
E
C
D
A
B
End View
Side View Figure 1
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SD016774
Table II: Dimensional Data - English Units Nominal Size (in)
Working Pressure (psi)
A
B
C
D
E
F
(lb)
Number of Turns
1-13/16
10,000 15,000
18.25 18.00
9.06 9.88
(19.12) (19.12)
5.75 5.88
(21.38) (21.38)
14.00 14.00
240 280
12-1/3 12-1/3
2-1/16
2000 3000 5000 10,000 15,000
11.62 14.62 14.62 20.50 19.00
6.12 6.75 7.00 9.38 9.88
(17.25) (17.25) 19.38 (19.62) (19.88)
5.25 5.62 5.62 5.88 6.12
(19.62) (19.62) 21.62 (21.88) (25.00)
10.00 14.00 14.00 18.50 18.50
100 185 185 270 300
12-1/3 12-1/3 12-1/3 12-1/3 12-1/3
2-9/16
2000 3000 5000 10,000 15,000
13.12 16.62 16.62 22.25 21.00
7.12 7.62 9.25 9.81 11.50
(18.81) (18.81) (21.81) 21.00 (23.18)
6.00 6.50 7.38 6.81 7.94
(21.12) (21.12) (24.00) 23.31 (25.50)
10.00 14.00 14.00 18.50 18.50
150 230 230 370 560
15-1/8 15-1/8 15-1/8 15-1/8 15-3/4
3-1/8
2000 3000 5000
14.12 17.12 18.62
7.75 7.50 7.50
(22.81) (22.81) (22.81)
7.12 7.38 7.38
(25.00) (25.00) (25.00)
14.00 14.00 18.50
210 280 340
18-1/8 18-1/8 18-1/8
3-1/16
10,000 15,000
24.38 23.56
10.25 13.56
(23.88) (28.94)
8.06 9.25
(25.00) (30.18)
24.00 24.00
530 890
18-1/8 22-7/8
4-1/8
2000 3000 5000
17.12 20.12 21.62
9.75 10.50 10.81
(27.88) (27.88) (27.88)
9.12 9.12 9.12
(30.12) (30.12) (30.12)
18.50 18.50 18.50
350 450 540
23-1/4 23-1/4 23-1/4
4-1/16
10,000 15,000
26.38 29.00
12.81 14.60
(29.68) (44.81)
10.06 11.70
(31.00) (46.75)
24.00 24.00
870 1555
23-1/4 29-1/4
5-1/8
3000 5000 10,000
24.12 28.62 29.00
21.00 21.75 23.50
(33.31) 34.25 35.62
11.38 11.38 13.12
(34.50) 36.50 37.00
24.00 24.00 24.00
975 1100 1310
27-1/2 27-1/2 29
6-1/8
2000 3000 5000
22.12 24.12 29.00
12.38 12.75 14.12
(34.75) (34.75) (34.75)
12.88 12.88 12.88
(36.00) (36.00) (36.00)
18.50 24.00 24.00
800 1000 1220
33-3/4 33-3/4 33-3/4
6-3/8
2000 3000 5000 10,000
22.12 24.12 29.00 35.00
13.19 14.12 14.50 17.40
(34.75) (35.75) 35.75 39.00
12.90 12.90 12.90 14.70
(36.50) (36.50) 37.50 41.00
18.50 24.00 24.00 35.00
890 1020 1230 2500
33-3/4 33-3/4 33-1/4 43-1/8
7-1/16
3000 5000
28.12 32.00
17.38 17.38
(49.12) (49.12)
14.62 14.62
(60.00) (60.00)
43.00 43.00
1875 1975
46-1/2 46-1/2
9
5000
41.00
23.12
(55.62)
19.95
(66.75)
43.00
4100
59-1/4
Dimensions (in)
( ) = Approximate Dimension
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Weight
Dimensional Data
F 3.75" (95.25 mm)
E
C
D
A
B
End View
Side View Figure 1
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SD016774
Table II: Dimensional Data - Metric Units Nominal Size (in)
Working Pressure (psi)
A
B
C
D
E
F
(kg)
Number of Turns
1-13/16
10,000 15,000
463.55 457.20
230.12 250.95
(485.65) (485.65)
146.05 149.35
(543.05) (543.05)
355.60 355.60
108.86 127.00
12-1/3 12-1/3
2-1/16
2000 3000 5000 10,000 15,000
295.15 371.35 371.35 520.70 482.60
155.45 171.45 177.80 238.25 250.95
(438.15) (438.15) 492.25 (498.35) (504.95)
133.35 142.75 142.75 149.35 155.45
(498.35) (498.35) 549.15 (555.75) (635.00)
254.00 355.60 355.60 469.90 469.90
45.36 83.91 83.91 122.47 136.08
12-1/3 12-1/3 12-1/3 12-1/3 12-1/3
2-9/16
2000 3000 5000 10,000 15,000
333.25 422.15 422.15 565.15 533.40
180.85 193.55 234.95 249.17 292.10
(477.77) (477.77) (553.97) 533.40 (588.77)
152.40 165.10 187.45 172.97 201.68
(536.45) (536.45) (609.60) 592.07 (647.70)
254.00 355.60 355.60 469.90 469.90
68.04 104.33 104.33 167.83 254.01
15-1/8 15-1/8 15-1/8 15-1/8 15-3/4
3-1/8
2000 3000 5000
358.65 434.85 472.95
196.85 190.50 190.50
(579.37) (579.37) (579.37)
180.85 187.45 187.45
(635.00) (635.00) (635.00)
355.60 355.60 469.90
95.25 127.00 154.22
18-1/8 18-1/8 18-1/8
3-1/16
10,000 15,000
619.25 598.42
260.35 344.42
(606.55) (735.08)
204.72 234.95
(635.00) (766.57)
609.60 609.60
240.40 403.70
18-1/8 22-7/8
4-1/8
2000 3000 5000
434.85 511.05 549.15
247.65 266.70 274.57
(708.15) (708.15) (708.15)
231.65 231.65 231.65
(765.05) (765.05) (765.05)
469.90 469.90 469.90
158.75 204.12 244.94
23-1/4 23-1/4 23-1/4
4-1/16
10,000 15,000
670.05 736.60
325.37 370.84
(753.87) (1138.17)
255.52 297.18
(787.40) (1187.45)
609.60 609.60
394.63 705.33
23-1/4 29-1/4
5-1/8
3000 5000 10,000
612.65 726.95 736.60
533.40 552.45 596.90
(846.07) 869.95 904.75
289.05 289.05 333.25
(876.30) 927.10 939.80
609.60 609.60 609.60
422.25 498.95 594.21
27-1/2 27-1/2 29
6-1/8
2000 3000 5000
561.85 612.65 736.60
314.45 323.85 358.65
(882.65) (882.65) (882.65)
327.15 327.15 327.15
(914.40) (914.40) (914.40)
469.90 609.60 609.60
362.87 453.59 553.38
33-3/4 33-3/4 33-3/4
6-3/8
2000 3000 5000 10,000
561.85 612.65 736.60 889.00
335.03 358.65 368.30 441.96
(882.65) (908.05) 908.05 990.60
327.66 327.66 327.66 373.38
(927.10) (927.10) 952.50 1041.40
469.90 609.60 609.60 889.00
403.70 462.66 557.92 1133.98
33-3/4 33-3/4 33-3/4 43-1/8
7-1/16
3000 5000
714.25 812.80
441.45 441.45
(1247.65) (1247.65)
371.35 371.35
(1524.00) (1524.00)
1092.20 1092.20
850.49 895.84
46-1/2 46-1/2
9
5000
1041.40
587.25
(1412.75)
506.73
(1695.45)
1092.20
1859.73
59-1/4
Dimensions (mm)
( ) = Approximate Dimension
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Weight
D. Assembly Drawings and Parts Lists
34
1 2
8
3
9
5
4
6
10
7
11 12 13 14
21 15 22
16 17
23
18
2000 Thru 5000 psi WP 24
19
2000 Thru 5000 psi WP 25
20
(Shown 90° out of Position) 26
24 10,000 & 15,000 PSI WP
28
27
29
30
31
32
Figure 2 TC2FLS5K.DWG
TC1354
SD017018
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Parts List: FLS-TC Manual Gate Valve, Figure 2 Item
Recommended Spare Part
1
Stem Adapter
2
*
Pin (Shear)
3
*
O-Ring
4
Retainer Ring
5
*
O-Ring
6
*
Fusible Ring
7
Sleeve
8
Set Screw
9
Bearing Mount
10
Bearing Cap
11
*
12 13
Bearing Race Grease Fitting
*
Bearing, Roller
14
Spring
15
Packing Gland
16
Support Ring
17
*
Back-Up Ring
18
*
Stem Seal
19
Stud
20
Nut
21
Stem
22
Bonnet
23
Check Valve (Optional)
24
TC1354
Description
*
Gasket
25
Pin (Bonnet)
26
Grease Fitting
27
Retainer Plate
28
Gate
29
Seat
30
Seal O.D.
31
Seal I.D.
32
Body
33
Nameplate
34
Handwheel
15
40 1
8 2
9
3 10 41
11
4 12
5 6
13
7
14
7
15
16 18 17 19
20 21
Optional 23
22
25
29
(Shown 90° out of Position) 24
30 27
31
33 32
26
28
37
34
35
36
38
Figure 3 TC56.DWG
TC1354
SD017017
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Parts List: FLS-TC Manual Gate Valve, Figure 3 Item
Spare Part
Stem Adapter
22
*
Pin (Shear)
23
Collar
24
*
Grease Fitting
Grease Fitting
25
*
Check Valve (Optional)
5
Bearing Cap
26
Stem
6
Bearing Mount
27
Bonnet
7
Spring
28
8
Retainer Ring
29
Stud
Item
Spare Part
1 2
*
3 4
*
Description
Description Stem Seal Heat Shield (Optional)
*
Gate
9
*
O-Ring
30
Nut
10
*
Lip Seal
31
Hex Head Cap Screw
11
*
Ball Bearing
32
12
*
Fusible Ring
33
Pin (Bonnet)
13
*
Roller Bearing
34
Retainer Plate
14
Packing Gland
35
*
Seat
15
Pin (Dowel)
36
*
Seal O.D.
16
Spring Retainer
37
*
Seal I.D.
17
Bearing Cap Retainer
38
Body
18
Set Screw
39
Nameplate
19
*
20 21
TC1354
*
O-Ring
40
Support ring
41
Back-Up Ring
17
*
Gasket
Hand Wheel *
Wear Ring
32
1 2
8
3 9
5 6
4 7
10 11 12
33
13 16 14
17
15
18 19
20 Shown 90° out of Position
21
24
34 23
22
25
26
27
28
29
30
Figure 4 TC29SRL.DWG
TC1354
SD017016
18
Parts List: FLS-TC Manual Gate Valve, Figure 4 Item
Recommended Spare Part
1
Stem Adapter
2
*
Pin (Shear)
3
*
O-Ring
4
Retainer Ring
5
*
O-Ring
6
*
Fusible Ring
7
Sleeve
8
Set Screw
9
Bearing Mount
10
Bearing Cap
11
*
12 13
Bearing Race Grease Fitting
*
Roller, Bearing
14
Spring
15
Packing Gland
16
Support Ring
17
*
Back-Up Ring
18
*
Packing
19
Stud
20
Nut
21
Stem
22
Bonnet
23
TC1354
Description
*
Gasket (SRL)
24
Grase Fitting
25
Retainer Plate
26
Gate
27
Seat
28
Seal O.D.
29
Seal I.D.
30
Body
31
Nameplate
32
Handwheel
33
Heat Shield
34
Cap Screw
19
II. PERIODIC MAINTENANCE A. Lubricants 1. Recommended body cavity lubricant a. For normal operation, use Cameron standard valve grease, which is not affected by water or temperatures ranging from -20º to +250ºF. b. For continuous service below 0ºF, use one of the two available low temperature greases. c. For CO2 injection or very high CO2 production, use diesel-resistant grease. d. For continuous service above 180ºF, use one of the two available high temperature greases. e. Part numbers for ordering grease as well as selection guidelines are given in Table III.
With High CO2
E
P
F
P
700149
700667
700668*
700669
700670
-50°F to 250°F (-46°C to 121°C)
E
P
F
P
700123
700671
700672
700673
700674
-75°F to 350°F (-59°C to 177°C)
E
P
F
P
711027 711027-1
711027-2 711027-3 711027-4
E
E
G
G
713837 713837-1
713837-2 713837-3 713837-4
-0°F to 450°F (-18°C to 232°C)
G
P
F
P
700217
-20°F to 500°F (-29°C to 260°C)
G
P
F
P
710194 710194-1
Diesel
-0°F to 350°F (-18°C to 177°C)
High Temperature
E - Excellent (Recommended) G - Good (Recommended)
TC1354
F - Fair (Not Recommended) P - Poor (Not Recommended)
20
5 lb Can 700679
700680
700681
400 lb Drum
With H2S
-20°F to 250°F (-29°C to 121°C)
Resistant
Quantities (By Part Number) Available on a Standard Order Basis
120 lb Drum
Diesel
Standard
Low Temperature
Operational Properties
25 lb Pail
Service Temperature
(Per Pound)
Service
Standard Crude
Table III: Lubricant Selection
700682
710194-2 710194-3 710194-4
*Available in 20 lb pail only
2. Recommended thrust bearing lubricant a. For normal operation, use Cameron standard valve lubricant, which is not affected by water or temperatures ranging from -20º to +250ºF. b. For continuous service below 0ºF, use one of the two available low temperature greases. 3. Recommended anti-seize compound where specified, use High Nickel/High Temperature anti-seize compound, P/N 711227. B. Body Cavity Lubrication 1. Normal Operating Conditions Cameron lubricates gate valves on assembly. Lubricate the body cavity after ten operating cycles.* If the valve is removed from service, lubricate the body cavity before returning it to the line. a. Remove the grease fitting cap. Refer to Figures 5 and 6. 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 Table IV. * One cycle 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. 2. Unusual Temporary Operating Conditions If it becomes necessary to cement through, acidize through, or subject the valve to any other unusual service: a. Lubricate the valve body cavity before it is put into operation. b. Flush the valve with appropriate neutralizing fluid after it is removed from service. c. Operate the valve with fresh water or appropriate neutralizing fluid in the line. d. Lubricate the valve body cavity.
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Table IV: Grease Volume Requirements: Valve Size
Lubricant Volume Required
Lubricant Weight
Approximate Follower Plate Travel
(cu in)
(Liter)
(lb)
(kg)
(in)
(mm)
1-13/16” 10,000 psi WP
38
0.6
1.5
0.7
0.6
15
1-13/16” 15,000 psi WP
38
0.6
1.5
0.7
0.6
15
2-1/16” 2000 psi WP
43
0.7
1.7
0.8
0.7
18
2-1/16” 3000 psi WP
43
0.7
1.7
0.8
0.7
18
2-1/16” 5000 psi WP
43
0.7
1.7
0.8
0.7
18
2-1/16” 10,000 psi WP
43
0.7
1.7
0.8
0.7
18
2-1/16” 15,000 psi WP
43
0.7
1.7
0.8
0.7
18
2-9/16” 2000 psi WP
79
1.3
3.2
1.5
1.3
33
2-9/16” 3000 psi WP
79
1.3
3.2
1.5
1.3
33
2-9/16” 5000 psi WP
79
1.3
3.2
1.5
1.3
33
2-9/16” 10,000 psi WP
79
1.3
3.2
1.5
1.3
33
2-9/16” 15,000 psi WP
93
1.5
3.7
1.7
1.6
41
3-1/8” 2000 psi WP
114
1.9
4.6
2.1
1.9
48
3-1/8” 3000 psi WP
114
1.9
4.6
2.1
1.9
48
3-1/8” 5000 psi WP
114
1.9
4.6
2.1
1.9
48
3-1/16” 10,000 psi WP
114
1.9
4.6
2.1
1.9
48
3-1/16” 15,000 psi WP
155
2.5
6.2
2.8
2.6
66
4-1/8” 2000 psi WP
245
4.0
9.8
4.4
4.1
104
4-1/8” 3000 psi WP
245
4.0
9.8
4.4
4.1
104
4-1/8” 5000 psi WP
245
4.0
9.8
4.4
4.1
104
4-1/16” 10,000 psi WP
245
4.0
9.8
4.4
4.1
104
4-1/16” 15,000 psi WP
275
4.5
11.0
5.0
4.6
117
5-1/8” 3000 psi WP
312
5.1
12.5
5.7
5.2
132
5-1/8” 5000 psi WP
312
5.1
12.5
5.7
5.2
132
5-1/8” 10,000 psi WP
461
7.5
18.4
8.3
7.7
196
6-1/8” 2000 psi WP
583
9.5
23.3
10.6
9.8
249
6-1/8” 3000 psi WP
583
9.5
23.3
10.6
9.8
249
6-1/8” 5000psi WP
583
9.5
23.3
10.6
9.8
249
6-3/8” 2000 psi WP
583
9.5
23.3
10.6
9.8
249
6-3/8” 3000 psi WP
583
9.5
23.3
10.6
9.8
249
6-3/8” 5000 psi WP
583
9.5
23.3
10.6
9.8
249
6-3/8” 10,000 psi WP
575
9.4
23.0
10.4
9.7
246
7-1/16” 3000 psi WP
1250
20.5
50.0
22.7
21.0
533
7-1/16” 5000 psi WP
1250
20.5
50.0
22.7
21.0
533
9” 5000 psi WP
1250
20.5
50.0
22.7
21.0
533
C. Thrust Bearing Lubrication Lubricate the thrust bearings as often as required to ensure smooth valve operation. Pump grease into the automotive type fitting located in the bearing cap.
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III. TROUBLESHOOTING Table V Symptom
Possible Cause
Action
Fluid leaks past the gate and seat assembly.
1. Gate or seats are worn. 2. Handwheel is not backed off.
Replace the gate or seats. Back off the handwheel ¼ turn.
Fluid leaks around the valve stem.
Stem packing is worn.
Replace the stem packing.
Fluid leaks at the bonnet flange.
1. Bonnet seal ring is damaged. 2. Bonnet or body ring groove is damaged.
Replace the bonnet seal ring.
Fluid leaks from the bonnet grease fitting.
Check valve inside the grease fitting is worn or contains debris.
Replace the grease fitting.
Handwheel is hard to turn.
1. Thrust bearings have lost lubricant. 2. Thrust bearings are corroded. 3. Gate and stem threads have lost lubricant.
Lubricate the thrust bearings. Replace the thrust bearings.
Stem shear pin is sheared.
Replace the stem shear pin.
Handwheel turns without opening or closing the valve.
Return the valve to Cameron for repair.
Lubricate the gate and stem through the bonnet grease fitting.
IV. 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-ofmaterial. 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 lists, Part ID 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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V. STEM SHEAR PIN REPLACEMENT A. Procedure for design with shear pin retained by set screws as shown in Figure 2. Item numbers in parentheses refer to Figure 2. The two shear pins (item 2) can be replaced with pressure in the valve, with the gate in any position (open to closed), and without engaging the stem backseat. The pin through the stem adapter (1) and stem (21) is subjected to operating torque only. The pin through the bearing mount (9) and stem (21) locks the bearing mount position on the stem. 1. Remove the handwheel (34). 2. Remove the two set screws (8) from the stem adapter (1). 3. Remove the stem adapter-to-stem pin using a small hammer and punch. If the pin has sheared, it probably will not come out - do not try to force it. Pull the stem adapter (1) off the stem and remove sheared pieces of the pin from both parts. 4. Remove the bearing mount-to-stem pin using a small hammer and punch. Maintain the rotational position of the bearing mount (9) with respect to the stem. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 5. Reinstall both pins if in good condition, or replace with new pins as needed per the Cameron part number for the specific valve. 6. Replace the two stem adapter set screws (8). 7. Replace the handwheel (34). B. Procedure for design with shear pins retained by a collar as shown in Figure 3. Item numbers in parentheses refer to Figure 3. The two shear pins (item 2) can be replaced with pressure in the valve, with the gate in any position (open to closed), and without engaging the stem backseat. The pin through the stem adapter (1) and stem (26) is subjected to operating torque only. The pin through the bearing mount (6) and stem (26) locks the bearing mount position on the stem. 1. Remove the handwheel (40).
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2. Remove the retainer ring (8). 3. Remove the collar (3), held only by friction of O-ring, lip seal, etc. 4 Remove the stem adapter-to-stem pin using a small hammer and punch. If the pin has sheared, it probably will not come out - do not try to force it. Pull the stem adapter (1) off the stem and remove sheared pieces of the pin from both parts. 5. Remove the bearing mount-to-stem pin using a small hammer and punch. Maintain the rotational position of the bearing mount (6) with respect to the stem. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 6. Reinstall both pins if in good condition, or replace with new pins as needed per the Cameron part number for the specific valve. 7. Clean and grease surfaces of the collar (3) that contact the bearing cap lip seal (10) and the stem adapter O-ring (9). Replace the collar. 8. Replace the retainer ring (8). 9. Replace the handwheel (40). VI. BACKSEAT SEAL ENGAGEMENT (Stem/Bonnet) It may be desirable to backseat the valve due to stem seal leakage or to perform maintenance procedures that require backseating. A. Procedure for Designs with Shear Pin Retained by Set Screws as Shown in Figure 2. Item numbers in parentheses refer to Figure 2. 1. Remove the handwheel (34). 2. Remove the two set screws (8) from the stem adapter (1). 3. Remove the stem adapter-to-stem shear pin (2) using a small hammer and punch. 4. Remove the stem adapter (1) from the stem (21). 5. Remove the bearing mount (9)-to-stem shear pin (2).
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6. Prevent stem rotation with a high strength rod through the stem adapter shear pin hole in the stem. Then use the wrenching flats to turn the bearing mount (9) clockwise (to the right) to move the stem and gate (28) until the stem backseat shoulder firmly contacts the bonnet. B. Procedure for Designs with Shear Pins Retained by Collar as Shown in Figure 3. Item numbers in parentheses refer to Figure 3. 1. Remove the handwheel (40). 2. Remove the collar retainer ring (8). 3. Remove the collar (3). 4. Remove the bearing mount (9)-to-stem shear pin (2), but do not remove the stem adapter (1)-to-stem shear pin (2). 5. Prevent stem rotation with a wrench on the stem adapter (1). Then use the wrenching flats to turn the bearing mount (9) clockwise (to the right) to move the stem and gate (28) until the stem backseat shoulder firmly contacts the bonnet. C. Alternates: Using ‘Conventional’ Backseating Procedures. The following ‘standard’, more familiar backseating procedures used for most Cameron gate valve models may also be used. The previously described procedures, A or B, require considerably less effort (torque) to backseat an FLS-TC valve. 1. Procedure for Conventional Threaded Bearing Cap Designs as Shown
in Figure 2. Item numbers in parentheses refer to Figure 2. a. Close the valve fully. b. Loosen the bearing cap (10) – turn counterclockwise (to the left) four complete turns. c. Turn the handwheel clockwise (in the closing direction) until the gate firmly contacts the bottom of the body cavity and the stem moves outward until the backseat shoulder contacts the bonnet. d. ‘Bump’ the handwheel in the closing direction for firm backseat contact.
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2. Procedure for Designs with Bearing Cap Retained by a Threaded Retainer as Shown in Figure 3. Item numbers in parentheses refer to Figure 3. a. Close the valve fully. b. Loosen the bearing cap retainer (17) – turn counterclockwise (to the left) four complete turns. c. Turn the handwheel clockwise (in the closing direction) until the gate firmly contacts the bottom of the body cavity and the stem moves outward until the backseat shoulder contacts the bonnet. d. ‘Bump’ the handwheel in the closing direction for firm backseat contact. VII. BACKSEAT SEAL VERIFICATION A. For Valves Rated 10,000 psi (69 Mpa) WP and Below Refer to Figure 2 and Figure 5. Note: As an option, the high pressure fitting (Refer to Section VII.B.) may be utilized in a valve rated at 10,000 psi (69 Mpa) and below. 1. Remove the grease fitting cap.
1/8" Diameter Pin
Bonnet
Pressure In Bonnet
Grease Fitting Body
2. Unseat the ball in the grease fitting check valve by inserting a .125” (3.1 mm) diameter by .75” (19 mm) long pin into the run of the fitting.
Grease Fitting Cap Pressure Bleed By
SD-10268-99
Figure 5 - Low Pressure Grease Fitting
3. Replace the cap slowly until the check valve ball in the fitting is unseated, and the pressure trapped by the backseating process is vented. 4. If pressure escapes quickly and then stops, valve body pressure is being held either by the backseat, or possibly by a “buried” check valve (23) in the grease fitting flow port (located as shown in Figure 2 or perhaps deeper into the port, particularly for a clad valve).
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Note: Standard FLS-TC gate valves do not have a “buried” check valve in the grease fitting flow port. However, an extra check valve may be present in a ‘special’ valve bonnet. Therefore it is important to review the bill of material for the specific valve being serviced, and the assembly drawing referenced on the bill, to determine if there is a buried check valve in the grease port. a) Remove the grease fitting cap. b) Remove the grease fitting from the bonnet. c) Remove the .125” (3.1mm) diameter pin from the grease fitting. 5. Determine whether or not a “buried” check valve is installed in the grease fitting flow port. If no buried check valve exists, the backseat seal has been verified in previous step 4. If the bonnet grease port contains a buried check valve, proceed to Paragraph C on page 29. B. For Valves Rated 15,000 psi (103.5 Mpa) WP and Above Refer to Figure 6. Note: The standard high pressure grease fitting is a special metal sealing fitting containing a check valve. The bonnet port is a special configuration with a straight thread, rather than a pipe thread, which accepts only this fitting design. As an option, the high pressure fitting may be incorporated in a valve rated at less than 15,000 psi. Do not use PTFE tape or thread sealant on these fittings. 1. Remove the grease fitting cap.
Grease Fitting Body
Bonnet Grease Fitting Cap
Pressure In Bonnet
Pressure Bleed By
Grease Fitting Gland
Hex
SD-10267-99
Figure 6 - High Pressure Grease Fitting
2. Loosen the fitting approximately one turn (counterclockwise rotation) to unseat the metal seal, releasing pressure trapped by the backseating process.
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3. If pressure escapes quickly and then stops, valve body pressure is being held either by the backseat, or possibly by a “buried” check valve (23) in the grease fitting flow port (located as shown in Figure 2, or perhaps deeper into the port, particularly for a clad valve). Note: Standard FLS-TC gate valves do not have a “buried” check valve in the grease fitting flow port. However, an extra check valve may be present in a ‘special’ valve bonnet. Therefore it is important to review the bill of material for the specific valve being serviced, and the assembly drawing referenced on the bill, to determine if there is a buried check valve in the grease port. a) Remove the grease fitting cap. b) Remove the grease fitting from the bonnet. 4. Determine whether or not a “buried” check valve is installed in the grease fitting flow port. If no buried check valve exists, the backseat seal has been verified in previous step 3. If the bonnet grease port contains a buried check valve, proceed to Paragraph C below. C. For Valves with Special “Buried” Check Valve Below Grease Fitting If the bonnet grease port contains a buried check valve, then valve body pressure must be vented through the buried check valve to determine if the backseat seal is effective. Unseat the ball in the buried check valve using a special Cameron unseating tool. Refer to the valve bill of material for the tool part number. 1. Using the unseating tool, unseat the buried check valve to vent pressure trapped by the backseating process. 2. If pressure escapes quickly and then stops, valve body pressure is being held by the backseat. The backseat seal and the buried check valve seal have been verified to be effective. a) Replace the bonnet grease fitting (with cap removed). b) Install the grease fitting cap. 3. If no pressure escapes, valve body pressure is being held by the backseat. However, the buried check valve is apparently defective (leaking). a) Remove the buried check valve unseating tool and replace the buried check valve. b) Replace the bonnet grease fitting (with cap removed). c) Install the grease fitting cap. TC1354
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4. If pressure continues to escape, the backseat seal is ineffective. a) Remove the buried check valve unseating tool. b) Replace the bonnet grease fitting (with cap removed). c) Install the grease fitting cap. d) Repeat the Backseat Seal Engagement procedure per Section VI. e) Repeat Step VII: Backseat Seal Verification. VIII. BACKSEAT SEAL DISENGAGEMENT AND BEARING MOUNT ADJUSTMENT A. Procedure for Designs with Shear Pin Retained by Set Screws as Shown in Figure 2 (Reference Section VI.A.). Item numbers in parentheses refer to Figure 2. 1. Prevent stem rotation with a high strength rod through the stem adapter shear pin hole in the stem (21). Then use the wrenching flats to turn the bearing mount (9) counterclockwise (to the left) one full turn and continue until opposing shear pin holes (or slots) in the bearing mount align with the shear pin hole in the stem (should be less than an additional ½ turn). 2. Reinstall the bearing mount-to-stem pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. 3. Install the stem adapter (1) on the stem, aligning the shear pin holes through both parts. Reinstall the stem adapter-to-stem shear pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 4. Replace the two stem adapter set screws (8). 5. Replace the handwheel (34).
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B. Procedure for Designs with Shear Pins Retained by Collar as Shown in Figure 3. (Reference Section VI.B.) Item numbers in parentheses refer to Figure 3. 1. Prevent stem rotation with a wrench on the stem adapter (1). Then use the wrenching flats to turn the bearing mount (9) counterclockwise (to the left) one full turn and continue until opposing shear pin holes (or slots) in the bearing mount align with the shear pin hole in the stem (should be less than an additional ½ turn). 2. Reinstall the bearing mount-to-stem pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. 3. Install the stem adapter (1) on the stem, aligning the shear pin holes through both parts. Reinstall the stem adapter-to-stem shear pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 4. Clean and grease surfaces of the collar (3) that contact the bearing cap lip seal (10) and the stem adapter o-ring (9). Install the collar over the stem adapter and bearing mount. 5. Install the collar retainer ring (8) on the stem adapter. 6. Install the handwheel (40) on the stem adapter. C. Alternates: Using ‘Conventional” Procedures to Disengage Backseat Without Affecting Bearing Mount Adjustment. 1. Procedure for Conventional Threaded Bearing Cap Designs as Shown in Figure 2. Item numbers in parentheses refer to Figure 2. a. Turn the handwheel counterclockwise (to the left) a partial turn to move the gate slightly away from the bottom of the body cavity (torque may be relatively high due to stem backseat shoulder contact with bonnet).
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b. Turn the bearing cap (10) clockwise (to the right), pushing the stem off backseat, until the gate contacts the bottom of the body cavity (indicated by a marked increase in torque). c. Repeat steps a) and b) until the bearing cap is completely made up on the bonnet and tighten to 200 ft.-lb. (271 N•m) Torque. d. Verify that the gate was not locked against the bottom of the body cavity when tightening the bearing cap. Turn the handwheel counterclockwise (opening direction) to verify gate freedom of movement (torque will be proportional to gate friction due to pressure in valve). If necessary, loosen the bearing cap and repeat steps a through d. e. Place the valve in the fully closed or fully open position. Caution: Verify that it is safe with respect to pressure, fluids, etc. in the Christmas tree, flow lines, and other equipment before opening the valve. 2. Procedure for Designs with Bearing Cap Retained by a Threaded Retainer as Shown in Figure 3. Item numbers in parentheses refer to Figure 3. a. Turn the handwheel counterclockwise (to the left) a partial turn to move the gate slightly away from the bottom of the body cavity (torque may be relatively high due to stem backseat shoulder contact with bonnet). b. Turn the bearing cap retainer (17) clockwise (to the right), pushing the stem off backseat, until the gate contacts the bottom of the body cavity (indicated by a marked increase in torque). c. Repeat steps a) and b) until the bearing cap retainer is completely made up on the bonnet and tightened to 300 ft.-lb. (407 N•m) Torque. d. Verify that the gate was not locked against the bottom of the body cavity when tightening the bearing cap retainer. Turn the handwheel counterclockwise (opening direction) to verify gate freedom of movement (torque will be proportional to gate friction due to pressure in valve). If necessary, loosen the bearing cap retainer and repeat steps a through d. e. Place the valve in the fully closed or fully open position. Caution: Verify that it is safe with respect to the Christmas tree, flow lines, and other equipment before opening the valve.
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IX. BONNET GREASE FITTING REPLACEMENT A. For Valves Rated 10,000 psi (69 Mpa) WP and Below. Item numbers in parentheses refer to Figure 2. Refer to Figure 5 - Low Pressure Grease Fitting. Note: As an option, the high pressure fitting may be utilized in a valve rated at 10,000 psi (69 Mpa) and below. Refer to Section IX.B. 1. Engage backseat seal (stem/bonnet) per Section VI. 2. Verify that the backseat is sealing per Section VII. 3. Remove the low pressure grease fitting from the valve bonnet. It is a tapered pipe thread connection. 4. Clean the threads in the bonnet port and on the new fitting as needed. 5. Apply PTFE tape or other thread sealant to the grease fitting threads. 6. Remove the cap from the new grease fitting. Caution: Applying torque to the cap during installation could damage the fitting. 7. Install the grease fitting. 8. Install and tighten the cap on the fitting. 9. Disengage backseat and adjust bearing mount per Section VIII. B. For Valves Rated 15,000 psi (103.5 Mpa) WP and Above Refer to Figure 6 - High Pressure Grease Fitting. 1. Engage backseat seal (stem/bonnet) per Section VI. 2. Verify that the backseat is sealing per Section VII. 3. Remove the high pressure grease fitting from the valve bonnet. 4. Remove the cap from the new grease fitting. Caution: Installing the high pressure grease fitting with the cap in place prevents the fitting from seating properly. 5. Install the new fitting in the bonnet, applying 80 to 100 ft-lb (108 to 136 N•m) torque. 6. Install and tighten the cap on the fitting. TC1354
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7. Disengage backseat and adjust bearing mount per Section VIII. X. THRUST BEARING REPLACEMENT AND FUSIBLE RING INSPECTION A. Procedure for Conventional Threaded Bearing Cap Designs as Shown in Figure 2. Item numbers in parentheses refer to Figure 2. 1. Thrust Bearing Removal a. Engage backseat seal (stem/bonnet) per Section VI. Note: Backseat verification (Section VII) is not necessary for this thrust bearing replacement procedure since the stem seal (18) will be retained throughout the procedure by the packing gland (15). b. The stem adapter (1) should already be removed after the backseat procedure in previous Step a. c. Remove the bearing cap (10) from the bonnet (22). Turn counterclockwise (to the left) to disengage from the bonnet threads. d. Remove the outer thrust bearing (13) and two races (11) from the bearing mount (9), or from inside the bearing cap (10). e. Verify that the retainer ring (4) for the fusible ring sleeve (7) is positioned within 1/16 in. (1.6 mm) from the top of the bearing cap (10). This is an indication that the fusible ring (6) is intact inside the bearing cap. f. If the gap between the retainer ring (4) and the top of the bearing cap exceeds 1/8 in. (3.2 mm), the fusible ring may be too thin after having been compressed by pressure force when subjected to excessive heat. 1) Remove the retainer ring (4). 2) Place the bearing cap upright in a hydraulic press and press down on the inner sleeve (7) until it becomes loose inside the bearing cap. 3) Remove the fusible ring (6) from inside the bearing cap or from the shoulder of the sleeve (7). A hammer and chisel may be required to cut the fusible ring for removal. It is a relatively soft metal or plastic ring. g. Remove the bearing mount (9) from the stem (21). Prevent stem rotation with a rod through the stem adapter shear pin hole in the stem (26). Then use the wrenching flats to turn the bearing mount counterclockwise (to the left) to disengage from the stem threads. TC1354
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h. Remove the inner thrust bearing (13) and two races (11) from above the springs (14) or from the bearing mount (9). 2. Thrust Bearing Installation a. Clean all parts prior to assembly. Use the same grease for the thrust bearings and for assembly purposes as the body filler grease specified on the bill of material for the specific valve. Use High Nickel/High Temperature Anti-seize compound wherever anti-seize is specified. b. Verify that the Belleville springs (14) adjacent to the packing gland (15) are oriented in ’series’, as shown in Figure 2. c. Apply grease to one roller bearing and two races. Place the bearing between two races and place over the end of the bearing mount (9) that will be adjacent to the springs (14), positioned as shown. d. Apply anti-seize to the threads in the bearing mount (9) and to the mating threads on the stem (21). Thread the bearing mount onto the stem by hand (clockwise rotation) until the bearing race firmly contacts the outer spring, aligning the end of the bearing mount inside the inner diameter of the springs (14). e. Apply grease to one roller bearing and two races. Place the bearing between two races and place over the shear pin end of the bearing mount, positioned as shown. f. If required, reassemble fusible ring components into the bearing cap. Refer to previous Step 1.f). 1) Install a new fusible ring (6) inside the bearing cap. 2) Apply anti-seize to the inside and outside surfaces of the fusible ring retainer sleeve (7) and install inside the bearing cap. 3) Install the sleeve retainer ring (4). g. Apply anti-seize to the threads in the bearing cap (10) and the mating threads on the bonnet (22). h. Thread the bearing cap onto the bonnet (clockwise rotation) until the inner sleeve (7) contacts the packing gland (15). Tighten to 200 ft.-lb.(271 N•m) torque.
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i. Adjust the stem backseat shoulder to its normal operating position. 1) Prevent stem rotation with a rod through the stem adapter shear pin hole in the stem (21). Then use the wrenching flats to turn the bearing mount clockwise (to the right) until the stem backseat shoulder contacts the bonnet (indicated by the bearing mount becoming tight on the stem). 2) Continue to prevent stem rotation. Use the wrenching flats to turn the bearing mount counterclockwise (to the left) 1½ turns and continue turning until opposing shear pin slots (or holes) in the bearing mount align with the shear pin hole in the stem (should be less than an additional ½ turn). 3) Reinstall the bearing mount-to-stem pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. 4) Install the stem adapter (1) on the stem, aligning the shear pin holes through both parts. Reinstall the stem adapter-to-stem shear pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 5) Replace the two stem adapter set screws (8). 6) Replace the handwheel (34). 7) Lubricate the thrust bearings through the grease fitting in the bearing cap per Sections II.A.2. and II.C. in this manual. B. Procedure for Designs with Bearing Cap Retained by a Threaded Retainer as Shown in Figure 3. Item numbers in parentheses refer to Figure 3. 1. Thrust Bearing Removal a. Engage backseat seal (stem/bonnet) per Section VI. Note: Backseat verification (Section VII) is not necessary for this thrust bearing replacement procedure since the stem seal (22) will be retained throughout the procedure by the packing gland (14).
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b. The collar (3) should already be removed after the backseat procedure in previous Step a. c. Remove the optional heat shield (23) if so equipped. Remove the cap screws (31) which secure the two halves of the heat shield. d. Verify that the bearing cap (5) is held firmly against the bonnet (27) by the bearing cap retainer (17). Looseness may indicate that the fusible ring (12) is too thin after having been compressed by pressure force when subjected to excessive heat. e. Remove the bearing cap retainer set screws (18). f. Remove the bearing cap retainer (17) from the bonnet (27). Turn counterclockwise (to the left) to disengage from the bonnet threads. g. Check the condition of the fusible ring (12). It may be inside the retainer ring (17) or on the shoulder of the bearing cap (5). The fusible ring may be reused if in good condition. h. If necessary, replace the fusible ring (12). A hammer and chisel may be required to cut the ring for removal. It is a relatively soft metal or plastic. i. Remove the roller thrust bearing (11) from the bearing mount (6). j. Remove the bearing mount (6) from the stem (26). Prevent stem rotation with a wrench on the stem adapter (1). Then use the wrenching flats to turn the bearing mount (6) counterclockwise (to the left) to disengage from the stem threads. k. Remove the tapered roller bearing (13) from the top of the spring retainer (16) or from the bearing mount (6). 2. Thrust Bearing Installation a. Clean all parts prior to assembly. Use the same grease for the thrust bearings and for assembly purposes as the body filler grease specified on the bill of material for the specific valve. Use High Nickel/High Temperature Anti-seize compound wherever anti-seize is specified. b. Verify that the Belleville springs (7) adjacent to the packing gland (14) are oriented in ‘series’, as shown in Figure 3.
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c. Pack the tapered roller bearing (13) with grease and place over the end of the bearing mount (6) that will be adjacent to the spring retainer (16). d. Apply anti-seize to the threads in the bearing mount (6) and to the mating threads on the stem (26). Thread the bearing mount onto the stem by hand (clockwise rotation) until the tapered roller bearing firmly contacts the spring retainer (16). e. Pack the roller bearing (11) with grease and place over the shear pin end of the bearing mount, positioned as shown. f. Install the bearing cap (5) over the bearings and bearing mount, aligning the two bearing cap pins (15) with the matching holes in the bonnet. g. Install the fusible ring (12) on the bearing cap, located as shown. h. Apply anti-seize to the threads in the bearing cap retainer (17) and the mating threads on the bonnet (27). i. Thread the bearing cap retainer onto the bonnet (clockwise rotation) until it contacts the fusible ring (12). Tighten to 300 ft.-lb. (407 N•m) torque. j. Install the four locking set screws (18) in the bearing cap retainer ring (17) and tighten evenly against the bonnet. k. Replace the two piece optional heat shield (23) if so equipped. Retain with four cap screws (31) threaded into the bonnet (27). l. Adjust the stem backseat shoulder to its normal operating position. 1) Install the stem adapter (1) in the stem, aligning the shear pin holes through both parts. Reinstall the stem adapter-to-stem shear pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. 2) Prevent stem rotation with a wrench on the stem adapter (1). Then use the wrenching flats to turn the bearing mount clockwise (to the right) until the stem backseat shoulder contacts the bonnet (indicated by the bearing mount becoming tight on the stem).
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3) Continue to prevent stem rotation. Use the wrenching flats to turn the bearing mount counterclockwise (to the left) ½ turn and continue turning until opposing shear pin holes (or slots) in the bearing mount align with the shear pin hole in the stem (should be less than an additional ½ turn). 4) Reinstall the bearing mount to stem pin if in good condition, or replace with a new pin per the Cameron part number for the specific valve. Caution: The two shear pins are made from a specific material, heat treated to a closely controlled strength. Therefore, do not substitute different pins. This could result in premature shearing of a pin during valve operation, or damage to valve components. Use only replacement pins per the part number on the Cameron bill of material for the specific valve being serviced. 5) Clean and grease the surfaces of the collar (3) that contact the bearing cap lip seal (10) and the stem adapter o-ring (9). Replace the collar. 6) Replace the retainer ring (8). 7) Replace the handwheel (40). XI. STEM SEAL REPLACEMENT WITH PRESSURE IN VALVE Note: Item numbers in parentheses refer to Figure 2. A. Stem Seal Removal 1. Engage backseat seal (stem/bonnet) per Section VI. 2. Verify that the backseat is sealing per Section VII. 3. Remove the bearing mount and thrust bearings per Section X. 4. Remove the Belleville springs (14) from the packing gland (15). 5. Remove the packing gland (15). Turn counterclockwise until the threads disengage the bonnet threads. 6. Remove the stem seal and back-up ring (if applicable). a. Connect a grease gun to the bonnet grease fitting (26). Use the same grease as the body filler grease specified on the valve bill of material. Pump grease into the bonnet seal bore until the seal moves far enough out of the packing bore that grease no longer moves the seal, and begins to bypass around the seal OD. TC1354
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b. Continue seal removal using corkscrew tools, and other specialized removal tools. Caution: Be very careful not to scratch or otherwise damage the sealing surfaces of the stem OD, bonnet seal bore (including lead-in chamfer), etc., during seal removal, cleaning, and inspection. c. Disconnect the grease gun from the grease fitting. B. Stem Seal Installation 1. Carefully clean the grease from the bonnet seal bore so that a hydraulic lock will not prevent installation of the stem seal. 2. Inspect the sealing surfaces in the bonnet seal bore and stem OD to ensure they are clean and do not have scratches, corrosion, or other damage. 3. Apply a light coat of grease to: a. The stem OD sealing area and adjacent chamfer. b. The bonnet seal bore sealing area, lead-in chamfer, and threads. c. ID and OD of the stem seal and the backup ring, if applicable. d. The packing gland nose end and threads. 4. Install the stem seal over the stem and into the bonnet seal bore: a. J packing or U packing: Install with rounded nose facing pressure (facing bottom of bonnet seal bore). b. SLS or Varipak seal: Install with open end facing pressure. c. HT-20 seal: Contact Cameron Service Representative (special tools and training required; not user replaceable). 5. Using the packing gland as a pushing tool, push the packing into the bonnet seal bore. Push the seal until the packing gland threads can engage the bonnet threads. Then turn the packing gland clockwise (to the right) until it contacts the bonnet.
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6. If a back-up ring is used, remove the packing gland from the bonnet. Turn counterclockwise (to the left) to remove. Apply a light coat of grease to the stem OD. Install the back-up ring over the stem sealing OD. Use the packing gland to push the back-up ring over the stem until the packing gland threads can engage the bonnet threads. Turn the packing gland clockwise (to the right) until it contacts the bonnet, then tighten to approximately 200 ft-lb (271 N•m) torque. 7. Install remaining components including the bearing mount, thrust bearings, bearing cap, shear pins, stem adapter and handwheel per Section X. XII. GATE AND SEAT REPLACEMENT Note: Item numbers in parentheses refer to Figure 2 unless otherwise specified. A. Gate and Seat Removal 1. Vent all pressure from the valve. a. If the valve is not installed, ensure that at least one body end connection is vented to the atmosphere. Operate the handwheel to move the gate to approximately the half open position. This ensures that no pressure is trapped in the body cavity. b. If the valve is installed in a Christmas tree or other application, isolate the valve from well pressure or other pressure source. 1) Close adjacent valves upstream and downstream of the valve to be repaired. Ensure that the adjacent valves will remain closed during repair procedures. 2) Operate the handwheel to place the gate in approximately the half open position. Caution: If the handwheel is excessively hard to turn, verify that the stem is not backseated (contacting the bonnet). Perform the steps in Sections VI and VIII (VII not necessary) to be certain of correct bearing mount adjustment. 3) Vent all pressure from the body cavity and flow bore using the grease fitting venting procedure in Section VII. Leave the fitting in the venting configuration during this gate and seat replacement procedure. 2. Fully open the valve (turn the stem adapter (1) counterclockwise). 3. Support the weight of the heavy bonnet assembly with an appropriate lifting device.
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4. Loosen and remove the bonnet nuts (20). 5. Turn the stem adapter (1) clockwise until the stem threads (21) disengage the gate neck threads (28). 6. Remove the bonnet assembly. 7. Remove the Bonnet Gasket a. For Standard Flat or Ring Type Gasket Designs Remove by hand, being careful not to scratch or otherwise damage gasket sealing surfaces in the body or bonnet. b. For Special SRL Straight Bore Sealing Gasket Designs Note: Item numbers in parentheses refer to Figure 4. It is recommended that a new SRL gasket (23) be installed any time the bonnet has been removed. However, if necessary, the SRL gasket can normally be reused if it has not been scratched or otherwise damaged. An SRL gasket is most likely to be reused in circumstances such as lack of a new gasket, lack of the special installation and removal tool kit. If the SRL gasket is going to be reused, it should not be removed from the body (or bonnet if it remained in the bonnet upon disassembly). Also, the O.D. sealing surface of the gasket that is exposed beyond the body (or bonnet) face should be protected from damage by a thin wrap with duct tape or similar means. Normally, the SRL gasket will remain in the valve body when the bonnet is removed. In the event the gasket remains in the bonnet upon disassembly, the installation and removal tool kit can be used to remove the gasket from the bonnet. The following instructions are for removal of the SRL gasket from the valve body. Note: Item numbers in parentheses refer to Figure 7. 1) Attach the removal tool (1) to the SRL gasket ‘flange’ with cap screws (5). Lubricate the threads with valve assembly grease to prevent galling. 2) Install the all-thread rod (3) into the removal tool (1) to approximately one rod diameter depth. Lock in position with a hex nut (4) as shown.
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3) Place the load plate (2) over the threaded rod (3), contacting at least four bonnet studs, 90 degrees apart, that are installed to full normal depth in the valve body (so that the plate will be parallel to the body bonnet face). 4) Apply grease to all the all-thread rod threads that extend beyond the load plate. Apply grease to the hex nut threads and bottom face. Tighten the nut clockwise against the load plate to pull the SRL gasket out of the body.
5 2
1
3
4
SD-017330
Figure 7 - SRL Gasket Removal: Tighten Outer Nut (4) to Pull Gasket Out of Bore.
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Note: Item numbers in parentheses refer to figure 2. Caution: For a valve oriented with the flow bore vertical, such as in Christmas tree applications, do not remove the gate (28) until the upper seat (29) has been secured in position by special tooling. The heavy seat is free to fall when the gate is removed if not held in the seat pocket by special tooling. Refer to the bill of material for the specific valve being serviced for part numbers of seat installation/removal tooling (normally in the ‘Optional Items’ category of the bill of material). 8. Pull the gate (28) from between the seats (29). Caution: For T-slot type gates with separate gate neck, the gate neck is not mechanically fixed to the gate. A “T-head” on one end of the gate neck fits into a “T” shaped slot in the top of the gate. This loose connection allows free side to side movement of the gate neck with respect to the gate. 9. Remove the seats from the body. If necessary, pry the seats loose with a large screwdriver engaging the seat OD groove. 10. Remove the retainer plate (27) from the bottom of the body cavity. B. Parts Cleaning and Inspection 1. Clean the body cavity and body cavity parts. Be careful not to scratch or otherwise damage sealing surfaces. Sealing surfaces are identified in the following inspection instructions. 2. Inspect sealing surfaces for scratches, galling, corrosion, coating flaws, or other damage. 3. Inspect flat faces in both seat pockets in the body (32). 4. Inspect bonnet seal ring surfaces of the body (32) and bonnet (22). 5. Inspect front and back faces of both seats (29). 6. Inspect sealing lips of the seat lip seals (30 and 31). 7. Inspect both sides of the gate (28), and internal gate neck threads. 8. Inspect stem threads that engage the gate neck threads. 9. Inspect the retainer plate (27) for distortion, build-up of solid materials, etc. 10. Replace any damaged parts.
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C. Gate and Seat Installation 1. Install the Bonnet Gasket A. For Standard Flat or Ring Type Designs Standard bonnet gaskets should be installed just prior to bonnet installation as described later in this procedure. B. For Special SRL Straight Bore Sealing Gasket Designs Note: Item numbers in parentheses refer to Figure 8. 1) If the bonnet studs had been removed from the body, install the bonnet studs in the body. Apply anti-seize to the threads in the body and to the ‘short thread end’ of each stud. Thread the short thread end of each stud into the body until it ‘bottoms out’ with full thread engagement (engagement length equivalent to stud diameter). 2) Apply a light coating of valve assembly grease to the sealing surfaces on one end of the gasket, and to the sealing bore and lead-in chamfer in the body. 3) Place the gasket in the body counterbore, resting on the lead-in chamfer. Place the installation tool (1) over the gasket, contacting the gasket O.D. flange. Place the load plate (2) over the bonnet studs as shown, contacting the installation tool. For valves mounted horizontally, such as in a Christmas tree, it may be necessary to hold the SRL gasket in place by attaching the removal tool (1) to the SRL gasket flange with cap screws (5). 4) Apply anti-seize to the stud and bonnet nut threads. Install four bonnet nuts 90 degrees apart, hand tight, aligning the load plate (2) parallel with the bonnet face of the body. 5) Tighten the four bonnet nuts evenly in a criss-cross sequence (1,3,2,4), keeping the load plate parallel to the bonnet face, to press the gasket into the body counterbore. Continue until all four nuts are tight, indicating that the gasket flange has bottomed out in the body counterbore. 6) Remove the four bonnet nuts, load plate (2), and installation tool (1).
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1
2
SD-017326
Figure 8 - SRL Gasket Installation: using 4 Studs, 90° Apart, tighten Nuts Evenly.
2. Apply a coat of grease to the retainer plate (27) and place it in the bottom of the body cavity, oriented as shown in Figure 2. 3. Apply a very thin film of grease to the body seat pockets (22). 4. Apply a light coat of grease to the lip seals (30 and 31) and install in the seat grooves. 5. Apply a very thin film of grease to the back face of the seat (29), (lip seal side).
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Caution: A heavy coat of grease between the OD and ID lip seals (30 and 31) may cause damage or prevent installation of the gate into the valve. 6. Install the seats with lip seals into the body seat pockets, oriented with the lip seals contacting the body. 7. Pack the stem threads in the gate neck (28) with grease. 8. Apply a coating of grease to both faces and bottom lead-in chamfers of the gate, and to the faces of both seats. 9. Align the gate’s bottom edge lead-in chamfers with the seats and push the gate between the seats. Caution: For T-slot type gates with separate gate neck, the gate neck is not mechanically fixed to the gate. This loose connection allows free side to side movement of the gate neck with respect to the gate. Therefore, the gate neck must be held in place until the gate is moved far enough into the body that the seats retain the gate neck in the gate. 10. Apply a very light coating of grease to a new flat type or ring type bonnet gasket (24) and place on the bonnet face of the body. For special SRL gasket, refer to step C.1. 11. Using appropriate lifting equipment, lift the relatively heavy bonnet assembly and position adjacent to the bonnet face of the body. Orient the bonnet grease fitting toward the front side of the body, 90 degrees away from the valve bore. 12. Apply a coating of grease to the stem threads. 13. Engage the stem threads into the gate neck threads, rotating the stem counterclockwise (left hand thread). Thread the stem into the gate neck while moving the bonnet toward the body (guiding the bonnet stud holes over the studs) until the bonnet is in contact with the bonnet gasket, and the gate is pulled close to the bonnet. 14. Install the bonnet nuts and tighten in an even pattern. Refer to Table VI for torque requirements.
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Table VI: Recommended Bonnet Nut Torque The torque values shown in these tables are extracted from API 6A 17th Edition, Appendix D. The values are for user convenience only. They were calculated for two different bolt yield strengths: 105 KSI (i.e. B7) and 80KSI (i.e. B7M); and also for different coatings used on the bolts: ¦ = 0.13 (zinc/cadium plated) and ¦ = .07 (fluoropolymer such as Xylan 1052). All values shown assume that both the threads and nut face are well lubricated with thread dope or a suitable grease. Choose the bolt torque based on bolt size, material yield strength, and coating.
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Table VI - English Units
Valve Size
Stud Diameter D (in.)
Threads per in. N
1-13/16”10,000 psi WP
1.125
1-13/16”15,000 psi WP
1.250
2-1/16” 2000 psi WP
Studs with SY = 80 KSI Bolt Stress = 40 KSI
Studs with Sy = 105 KSI Bolt Stress = 52.5 KSI
Torque ¦ = 0.07 (ft-lb)
Torque ¦ = 0.13 (ft-lb)
Torque ¦ = 0.07 (ft-lb)
Torque ¦ = .013 (ft-lb)
8
305
523
401
686
8
421
726
553
953
0.625
11
52
88
68
115
2-1/16” 3000 psi WP
0.875
9
143
243
188
319
2-1/16” 5000 psi WP
0.875
9
143
243
188
319
2-1/16” 10,000 psi WP
1.125
8
305
523
401
686
2-1/16” 15,000 psi WP
1.250
8
421
726
553
953
2-9/16” 2000 psi WP
0.750
10
90
153
118
200
2-9/16” 3000 psi WP
1.000
8
213
361
279
474 474
2-9/16” 5000 psi WP
1.000
8
213
361
279
2-9/16”10,000 psi WP
1.250
8
421
726
553
953
2-9/16” 15,000 psi WP
1.500
8
733
1278
962
1677
3-1/8” 2000 psi WP
0.750
10
90
153
118
200
3-1/8” 3000 psi WP
0.875
9
143
243
188
319
3-1/8” 5000 psi WP
1.125
8
305
523
401
686
3-1/16” 10,000 psi WP
1.250
8
421
726
553
953
3-1/16” 15,000 psi WP
1.500
8
733
1278
962
1677
4-1/8” 2000 psi WP
0.875
9
143
243
188
319
4-1/8” 3000 psi WP
1.125
8
305
523
401
686
4-1/8” 5000 psi WP
1.250
8
421
726
553
953
4-1/16” 10,000 psi WP
1.625
8
934
1635
1226
2146
4-1/16” 15,000 psi WP
1.875
8
1440
2539
1890
3332
5-1/8” 3000 psi WP
1.125
8
305
523
401
686
5-1/8” 5000 psi WP
1.375
8
563
976
739
1281
5-1/8” 10 000 psi WP
1.375
8
563
976
739
1281
6-1/8” 2000 psi WP
1.000
8
213
361
279
474
6-1/8” 3000 psi WP
1.125
8
305
523
401
686
6-1/8” 5000 psi WP
1.375
8
563
976
739
1281
6-3/8” 2000 psi WP
1.000
8
213
361
279
474
6-3/8” 3000 psi WP
1.125
8
305
523
401
686
6-3/8” 5000 psi WP
1.375
8
563
976
739
1281
6-3/8” 10,000 psi WP
1.750
8
1169
2054
1534
2696
7-1/16” 3000 psi WP
1.500
8
733
1278
962
1677
7-1/16” 5000 psi WP
1.500
8
733
1278
962
1677
9” 5000 psi WP
1.500
8
733
1278
962
1677
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Table VI - Metric Units
Valve Size
Stud Diameter
Threads per in. N
Studs with SY = 550 Mpa Bolt Stress = 275 Mpa
Studs with Sy = 720 Mpa Bolt Stress = 360 Mpa
Torque ¦ = 0.07 (N • m)
Torque ¦ = 0.13 (N • m)
Torque ¦ = 0.07 (N • m)
8
413
706
540
925
8
569
981
745
1285
15.88
11
70
118
92
155
0.875
22.23
9
193
328
253
429
0.875
22.23
9
193
328
253
429
2-1/16” 10,000 psi WP
1.125
28.58
8
413
706
540
925
2-1/16” 15,000 psi WP
1.250
31.75
8
569
981
745
1285
2-9/16” 2000 psi WP
0.750
19.05
10
122
206
160
270
2-9/16” 3000 psi WP
1.000
25.40
8
288
488
376
639
D (In.)
(mm)
1-13/16”10,000 psi WP
1.125
28.58
1-13/16”15,000 psi WP
1.250
31.75
2-1/16” 2000 psi WP
0.625
2-1/16” 3000 psi WP 2-1/16” 5000 psi WP
Torque ¦ = .013 (N • m)
2-9/16” 5000 psi WP
1.000
25.40
8
288
488
376
639
2-9/16” 10,000 psi WP
1.250
31.75
8
569
981
745
1285
2-9/16” 15,000 psi WP
1.500
38.10
8
991
1727
1297
2261
3-1/8” 2000 psi WP
0.750
19.05
10
122
206
160
270
3-1/8” 3000 psi WP
0.875
22.23
9
193
328
253
429
3-1/8” 5000 psi WP
1.125
28.58
8
413
706
540
925
3-1/16” 10,000 psi WP
1.250
31.75
8
569
981
745
1285
3-1/16” 15,000 psi WP
1.500
38.10
8
991
1727
1297
2261
4-1/8” 2000 psi WP
0.875
22.23
9
193
328
253
429
4-1/8” 3000 psi WP
1.125
28.58
8
413
706
540
925
4-1/8” 5000 psi WP
1.250
31.75
8
569
981
745
1285
4-1/16” 10,000 psi WP
1.625
41.28
8
1263
2211
1653
2894
4-1/16” 15,000 psi WP
1.875
47.63
8
1947
3433
2549
4493
5-1/8” 3000 psi WP
1.125
28.58
8
413
706
540
925
5-1/8” 5000 psi WP
1.375
34.93
8
761
1320
996
1727
5-1/8” 10,000 psi WP
1.375
34.93
8
761
1320
996
1727
6-1/8” 2000 psi WP
1.000
25.40
8
288
488
376
639
6-1/8” 3000 psi WP
1.125
28.58
8
413
706
540
925
6-1/8” 5000 psi WP
1.375
34.93
8
761
1320
996
1727
6-3/8” 2000 psi WP
1.000
25.40
8
288
488
376
639
6-3/8” 3000 psi WP
1.125
28.58
8
413
706
540
925
6-3/8” 5000 psi WP
1.375
34.93
8
761
1320
996
1727
6-3/8” 10,000 psi WP
1.750
44.45
8
1581
2777
2069
3636
7-1/16” 3000 psi WP
1.500
38.10
8
991
1727
1297
2261
7-1/16” 5000 psi WP
1.500
38.10
8
991
1727
1297
2261
9” 5000 psi WP
1.500
38.10
8
991
1727
1297
2261
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P.O. Box 1212 Houston, TX 77251-1212 Ph: 713-939-2211 Fax: 713-939-2611 http://www.coopercameron.com
© Cooper Cameron Corporation, Cameron Division, Printed in USA 11/98 TC1354
