Cameron Fls Gate Valves s692o
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Operation and Maintenance Manual
Manually Actuated Cameron FL and FLS Gate Valves
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All the information in this manual is the exclusive property of Cameron International Corporation. Any reproduction or use of the calculations, drawings, photographs, procedures, or instructions, either expressed or implied, is forbidden without the expressed written permission of Cameron or its authorized agent.
Initial Release A1 April 1992 Revision B1 April 1994 Revision C1 June 1997 Revision D1 June 2005 Revision E1 February 2007 Revision F1 March 2008
Copyright © 2008 all rights reserved by Cameron International Corporation
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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 or injury 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 Cameron products, which are products of Cameron International Corporation. Cameron P.O. Box 1212 Houston, Texas 77251-1212 713-939-2211 http://www.c-a-m.com
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Table Of Contents I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Description and Features . B. Operation Instructions . . C. Dimensional Data . . . . . D. Parts List . . . . . . . . . .
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II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A. Lubrication . . . . . . . . . B. Lubrication Charts . . . . . . C. Body Cavity Lubrication . . . D. Thrust Bearing Lubrication .
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12 12 13 14
III. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IV. Bonnet Grease Fitting Replacement . . . . . . . . . . . . . . . . . . 15 A. Valves 10,000 psi and Below . . . . . . . . . . . . . . . . . . . 15 B. Valves 15,000 psi and Above . . . . . . . . . . . . . . . . . . . 16 V. Stem Pin and Thrust Bearing Replacement . . . . . . . . . . . . . . . 17 A. Removal of the Thrust Bearings . . . . . . . . . . . . . . . . . 17 B. Installation of the New Thrust Bearings . . . . . . . . . . . . . 18 VI. Stem Packing Replacement With Pressure In The Valve . . . . . . . 19 A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . 19 B. Installation of the New Packing . . . . . . . . . . . . . . . . . 21 VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . 23 A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . 23 B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . 23 C. Gate and Seat Assembly . . . . . . . . . . . . . . . . . . . . . 24 VIII. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . 27
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I. General Information
A. Description and Features The FL or FLS gate valve is a full-bore through-conduit valve designed and manufactured in accordance with ISO 10423, API 6A, and NACE MR-01-75. It is available in standard double flange, threaded-end, and special block body configurations. The following are standard features of the FL and FLS gate valves: 1. Sealing at the gate-to-seat and the seat-to-body is metal-to-metal. 2. The simplified gate and seat assembly has a minimum number of parts. One-piece seats and slab gate ensure reliable sealing and simplify field service. The modified Acme gate-to-stem thread allows the gate to move back and forth, or float, to seal against the seat. 3. The gate and seat assembly seals in both directions, and the gate and seats can be reversed for increased life. 4. The stem shoulder can be back seated against the bonnet to isolate the stuffing box, which allows field-replacement of the stem packing while the valve is under pressure. 5. The non-rising stem prevents a cavity pressure increase or displacement of cavity lubricant. 6. All FL and FLS valves have a specially designed, metal-to-metal sealing grease fitting which contains a check valve. The stem, gate, and seat are lubricated through the grease fitting which is located on the downstream side of the stem backseat for safety. No sealant or lubricant ports extend directly into the valve cavity. 7. The seal between the valve body and bonnet is a pressure-energized, BX-style metal bonnet gasket on 10,000 and 15,000 psi WP valves. Valves for 3000 and 5000 psi WP use a flat compression-type metal gasket. 8. API 6A Materials Classes and Temperature Classes are available, and other special trims area available upon request. Reduced-hardness bonnet bolting can be supplied for most sizes and pressures without downrating the working pressure. 9. With minor modifications, FLS valves can meet or exceed API 6FA fire safety requirements.
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10. Special non-elastomeric stem packing designs can extend the standard temperature rating of the FL or FLS Gate Valve up to 350o F (180oC), or down to -75o F (-60oC). These temperature ratings may not be available in all working pressures. 11. An optional add-on torque multiplier is available for larger FL and FLS valves to provide easier operation. 12. See the valve assembly bill-of materials for materials and descriptions of valve components.
B. Operation Instructions A gate valve should always be in either the full-open or full-closed position. Leaving the gate partially open or throttling through the valve could cause damage to the gate. The valve is opened by turning the handwheel counterclockwise (to the left) until it stops. Turning the handwheel back to the right ¼ turn will then relieve any stress in the stem, and is, therefore, recommended practice. Initial torque required to open the valve is given in Table I. The valve is closed by turning the handwheel clockwise (to the right) until it stops, and then backing off (counterclockwise) ½ to ¾ turn. The number of turns required to move the valve from full open to full closed is given in Table I. Table I: Operating Requirements 2000 - 3000 psi WP
5000 psi WP
Valve Bore Size -
2-1/16
2-9/16
3-1/8
4-1/16
5-1/8
6-3/8
2-1/16
2-9/16
3-1/8
4-1/16
5-1/8
6-3/8
Expected Opening Torque, Lubricated Valve, ft-lb
15
20
25
30
45
80
20
25
35
50
75
140
Maximum Opening Torque, Severe Service, ft-lb
30
40
60
80
130
235
45
65
95
135
220
395
Total Number of Turns, Full-Open to Full-Close
12-1/3
15-1/8
18-1/8
23-1/4
27-1/2
33-3/4
12-1/3
15-1/8
18-1/8
23-1/4
27-1/2
33-3/4
Valve Bore Size - Inch
1-13/16
2-1/16
2-9/16
3-1/16
4-1/16
5-1/8
1-13/16
2-1/16
2-9/16
3-1/16
Expected Opening Torque, Lubricated Valve, ft-lb
30
35
50
65
110
260*
50
60
100
125
Maximum Opening Torque, Severe Service, ft-lb
80
85
130
170
320
690*
125
155
265
335
12-1/3
12-1/3
15-1/8
18-1/8
23-1/4
29
12-1/3
12-1/3
15-3/4
22-7/8
Inch
10,000 psi WP
Total Number of Turns, Full-Open to Full-Close
15,000 psi WP
* Optional torque multiplier recommended. See manual #SD-1792.
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C. Dimensional Data
Table II: Dimensional Data - 2000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
6-1/8”
End-to-End, Flanged (Ring t)
11-5/8”
13-1/8”
14-1/8”
17-1/8”
22-1/8”
B
Extreme Width of Body
6-1/8”
7-1/8”
7-3/4”
9-3/4”
12-3/8”
C
Center of Port to Top of Stem Adapter
13”
33-13/16”
16-13/16”
18-7/16”
22-3/4”
D
Center of Port to Bottom of Body
5-1/4”
6”
7-1/8”
9-1/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
15-3/8”
16-1/8”
19-1/16”
20-11/16”
24”
F
Handwheel OD
14”
14”
14”
14”
18-1/2”
160 lb
200 lb
240 lb
350 lb
800 lb
A
Description
Weight (Flanged)
Table III: Dimensional Data - 3000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8"
A
End-to-End, Threaded
Description
10-5/8 ”
12-3/8”
13-5/8”
—
—
—
A
End-to-End, Flanged (Ring t)
14-5/8"
16-5/8"
17-1/8"
20-1/8”
24-1/8”
24-1/8”
B
Extreme Width of Body
6-3/4”
7-5/8 ”
7-1/2”
10-1/2”
21”
12-3/4”
C
Center of Port to Top of Stem Adapter
13”
33-13/16”
16-13/16”
18-7/16”
21-5/16"
22-3/4”
D
Center of Port to Bottom of Body
5-5/8”
6-1/2”
7-3/8”
9-1/8”
11-3/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
15-3/8”
16-1/8”
19-1/16”
20-11/16”
22-9/16”
24”
F
Handwheel OD Weight (Flanged)
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6-1/8”
14”
14”
14”
18-1/2”
24”
24”
170 lb
220 lb
260 lb
450 lb
750 lb
1000 lb
9
Table IV: Dimensional Data - 5000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8"
6-1/8”
A
End-to-End, Threaded
Description
10-5/8 ”
12-3/8”
13-5/8 ”
—
—
—
A
End-to-End, Flanged (Ring t)
14 -5/8"
16 -5/8"
18 -5/8”
21-5/8 ”
28-5/8 ”
29”
A
End-to-End, Butt Weld
—
—
—
21-1/2”
—
—
B
Extreme Width of Body
7”
8-3/16”
9-1/4”
10-13/16”
21-3/4”
14-1/8”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-15/16”
16-13/16”
18-7/16”
21-5/16"
22-3/4”
D
Center of Port to Bottom of Body
5-5/8”
6-1/2”
7-3/8”
9-1/8”
11-3/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
17-3/8”
18-1/8”
19-1/16”
20-11/16”
23-9/16”
24”
F
Handwheel OD
14”
14”
18-1/2”
18-1/2”
24”
24”
175 lb
230 lb
360 lb
520 lb
800 lb
1160 lb
Weight (Flanged)
Table V: Dimensional Data - 10,000 psi WP Item
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
5-1/8”
A
End-to-End, Flanged (Ring t)
Description
18-1/4”
20-1/2”
22-1/4”
24-3/8”
26-3/8”
29”
B
Extreme Width of Body
9-1/16”
9-3/8”
9-13/16”
10-1/4”
12-13/16”
23-1/2”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-1/8”
15-13/16”
16-7/8”
19-11/16”
23-7/8”
D
Center of Port to Bottom of Body
5-3/4”
5-7/8”
6-13/16”
8-1/16”
10-1/16”
13-1/8”
E
Center of Port to Top of Handwheel Rim
17-3/8”
17-3/8”
18-1/8”
18-1/16”
20-15/16”
25-1/4”
F
Handwheel OD
14”
18-1/2”
18-1/2”
24”
24”
24”
250 lb
275 lb
370 lb
480 lb
880 lb
1750 lb
Weight (Flanged)
Table VI: Dimensional Data - 15,000 psi WP Item
Description
A
End-to-End, Flanged (Ring t)
B
1-13/16”
2-1/16”
2-9/16”
3-1/16”
18”
19”
21”
23-9/16”
Extreme Width of Body
9-7/8”
9-7/8”
11-1/2”
13-9/16”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-1/8”
17-3/16”
20-15/16”
D
Center of Port to Bottom of Body
5-7/8”
6-1/8”
7-5/16”
9-1/4”
E
Center of Port to Top of Handwheel Rim
17-3/8”
17-3/8”
19-9/16”
22-3/16”
F
Handwheel OD
18-1/2”
18-1/2”
18-1/2”
24”
Weight
275 lb
300 lb
560 lb
890 lb
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D. Parts List
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II. Periodic Maintenance A. Lubrication 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
+250o F. b. For continuous service below 0° F, use one of the two available low temperature greases. c. For continuous service above 180o F, use one of the two available high temperature greases. d. Part numbers for ordering grease as well as selection guidelines are given in Table VIII. 2. Recommended stem bearing lubricant. a. For normal operation, use Cameron standard valve lubricant, which is not affected by water or temperatures ranging from -20o to
+250o F. b. For continuous service below 0° F, use one of the two available low temperature greases.
B. Lubrication Charts Table VII: Grease Volume Requirements Bore Size (in.)
Pressure Rating
Lubricant Volume
Lubricant Weight
Approximate Follower
Required (cu in.)
(lb)
Plate Travel (in.)
1-13/16"
2-9/16"
All All To 10,000 15,000
3-1/8”
To 5000
3-1/16”
10,000
3-1/16”
15,000
4-1/8”
To 5000
4-1/16”
10,000
38 43 79 93 114 114 155 245 243 312 461 583 583
1.5 1.7 3.2 3.7 4.6 4.6 6.2 9.8 9.7 12.5 18.5 23.3 23.3
.5 .7 1.3 1.6 1.9 1.9 2.6 4.2 4.1 5.3 7.8 9.9 9.9
2-1/16” 2-9/16"
5-1/8”
5000
5-1/8”
10,000
6-1/8”
To 5000
6-3/8”
To 5000
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Table VIII: Lubricant Selection
With H2S
With High C02
(Per Pound)
5 lb Can
25 lb Pail
120 lb Drum
400 lb Drum
-20oF to 250oF (-29oC to 121oC) -50oF to 250oF (-46oC to 121oC) Low Temp -75oF to 350oF (-59oC to 177oC) Diesel -0oF to 350oF Resistant (-18oC to 177oC) -0ooF to 450ooF (-18 C to 232 C) High o Temp -20 F to 500oF (-29oC to 260oC) E - Excellent (Recommended) G - Good (Recommended) Standard
Quantities (By Part Number) Available on a Standard Order Basis
Operational Properties
Diesel
Service Temperature
Standard Crude
Service
E
P
F
P
700149
700667
70668*
700669
700670
E
P
F
P
700123
700671
700672
700673
700674
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
G
P
F
P
700217
700679
700680
700681
700682
G
P
F
P
710194
710194-1
710194-2
710194-3
710194-4
F - Fair (Not Recommended) P - Poor (Not Recommended)
*Available in 20 lb pail only
C. Body Cavity Lubrication 1. Normal Operating Conditions Note: Cameron lubricates gate valves on assembly. Lubricate the body cavity after ten operating cycles. One cycle equals opening and closing the valve one time. The service interval can vary according to application, fluids used, and well conditions. If pressure is equalized across the valve before the valve is opened, the service interval can be extended. If the valve is removed from service, lubricate the body cavity before returning it to the line. a. Remove the grease-fitting cap located on the bonnet flange OD. b. Using either a bucket-type gun, P/N 19873-03, or hand-held type, P/N 19873-01, connect the grease gun coupler to the grease fitting. c. Pump the appropriate amount of lubricant into the body cavity. Refer to Part II, Paragraph B.
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2. Unusual Temporary Operating Conditions If it becomes necessary to cement through, acidize through, or subject the valve to any other unusual service, proceed as follows: a. Lubricate the valve body cavity before it is put into operation. b. Flush the valve with the appropriate neutralizing fluid in the line. c. Operate the valve with fresh water or appropriate neutralizing fluid in the line. d. Lubricate the valve body cavity.
D. Thrust Bearing Lubrication Note: Lubricate the thrust bearings as often as required to ensure smooth valve operation. 1. Using a hand-held grease gun, P/N 19873-01, connect the grease gun fitting to the hydraulic grease fittings with a hydraulic coupler. 2. Pump lubricant into the fittings until clean grease appears at the bleed port on the opposite side of the bearing cap.
III. Troubleshooting Symptom Fluid leaks past the gate and seat assembly.
1. Gate or seats are worn. 2. Handwheel is not backed off.
Action 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.
1. Bonnet seal ring is worn. 2. Bonnet or body ring groove oois damaged. Check valve inside the grease fitting is worn.
Replace the bonnet seal ring. Return the valve to Cameron for repair. Replace the grease fitting.
1. Thrust bearings have lost oolubricant.
Lubricate the thrust bearings.
2. Thrust bearings are corroded. 3. Gate and stem threads have oolost lubricant.
Replace the thrust bearings. Lubricate the gate and stem through the bonnet grease fitting.
Stem pin is sheared.
Replace the stem pin.
Fluid leaks at the bonnet flange. Fluid leaks from the bonnet grease fitting.
Handwheel is hard to turn.
Handwheel turns without opening or closing the valve.
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Caution: When a valve is used in the lower master valve position, on the outlet of a BOP or any other application in which it is the last surface barrier, precautions should be taken to ensure sub-surface safety barriers are in place and functioning. If valve bonnet maintenance is to be performed such as stem packaging replacement, bearing replacement or stem pin replacement consideration should be given with respect to number of barriers required by the customer and the local statutory requirements.
IV. Bonnet Grease Fitting Replacement
A. Valves 10,000 psi WP and Below 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 3. a. Remove the grease fitting cap. b. Trip the ball in the grease fitting check valve by inserting a 1/8” diameter by ¾” long pin into the run of the fitting. c. Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released. d. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. e. If pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. TC148
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2) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the grease fitting from the valve bonnet. 4. Install a new grease fitting. Caution: Installing the fitting with the cap in place could damage the cap. Do not install the fitting with the cap in place. 5. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb (33 N•m). b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap.
c. Tighten the bearing cap to approximately 200 ft-lb (270 N•m).
B. Valves 15,000 psi WP and Above Note: The standard grease fitting for 15,000 psi WP FL valves is a special metal-sealing, high pressure fitting, containing a check valve. The bonnet port housing this fitting is a special preparation without pipe threads which accepts only this type of fitting. Important: DO NOT use Teflon tape or thread sealant on these fittings. 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 4. TC148
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a. Remove the grease fitting cap. b. Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. c. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. d. If pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. 2) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the grease fitting from the valve bonnet. 4. Remove the cap from a new grease fitting and install the fitting in the bonnet. Torque to 80 to 100 ft-lb (100 to 135 N•m). 5. Install and tighten the cap on the fitting. Caution: Installing the fitting with the cap in place prevents the fitting from seating and could cause damage to the cap. Do not install the fitting with the cap in place. 6. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb (33 N•m). b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap. c. Tighten the bearing cap to approximately 200 ft-lb (270 N•m).
V. Stem Pin and Thrust Bearing Replacement Note: The stem thrust bearings can be replaced while the valve is under pressure in the line.
A. Removal of the Thrust Bearings 1. Loosen the bearing cap, using a 24” pipe wrench. After two or three turns, the cap will rotate freely by hand.
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Caution: If the cap does not rotate freely after three turns, the packing gland may be moving outward with the bearing cap. This can be checked by tapping on the stem adaptor so it moves relative to the bearing cap. If the stem adaptor does not move inward or continues to back out with the bearing cap, DO NOT remove the cap. Tighten the cap and a Cameron representative. 2. If the bearing cap rotates freely, remove the cap from the bonnet. 3. Using a punch, drive the stem pin from the stem adapter, ensuring that the adapter is not damaged. 4. Remove the adapter from the stem. Remove both sets of bearings and bearing races from the stem adapter. 5. Discard any pitted, cracked, or damaged bearings or races. 6. Replace the stem adapter if either of the bearing surfaces on the adapter shoulder is damaged.
B. Installation of the New Thrust Bearings. 1. Remove the new bearings from the protective packaging. 2. Pack the bearings with clean grease. 3. Place each bearing between a pair of carefully cleaned races. 4. Carefully clean the stem adapter. 5. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. 6. Insert the stem adapter over the end of the stem and align the pin hole in the adapter with the hole in the stem. 7. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer. 8. Replace the stem adapter O-ring if necessary. 9. Inspect the bearing cap to ensure that an extra race, held by grease tension, is not retained inside. TC148
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10. Clean the bearing cap and lubricate the threads. 11. Install the cap, and tighten to approximately 200 ft-lb (270 N•m). 12. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not ing the bonnet shoulder. 13. Inject grease through the bearing cap grease fittings until the excess grease es through the bleed port.
VI. Stem Packing Replacement with Pressure in the Valve
A. Removal of the Stem Packing 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Backseat the valve. a. Valves 10,000 psi WP and Below. Refer to Figure 3. 1) Remove the bonnet grease fitting cap. 2) Trip the ball in the grease fitting check valve by inserting an 1/8” diameter by ¾” long pin into the run of the fitting. 3) Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped b the backseating process is released. 4) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 5) If pressure continues to escape, the backseat in ineffective. a) Backseat the valve again. Repeat steps 1 and 2.
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b) If the backseat continues to be ineffective, a Cameron representative. b. Valves 15,000 psi WP and Above. Refer to Figure 4. 1) Remove the grease fitting cap. 2) Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. 3) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 4) If pressure continues to escape, the backseat in ineffective. a) Backseat the valve again. Repeat steps 1 and 2. b) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the handwheel and bearing cap. 4. Remove the cap from the bonnet. 5. Using a punch, drive the stem pin from the stem adapter, ensuring that the adapter is not damaged. 6. Remove the adapter from the stem. 7. Remove both sets of bearings and bearing races from the stem adapter. 8. Loosen the packing gland. 9. Ensure that the threads on the bonnet neck OD are not damaged. 10. Remove the packing gland. 11. Remove the stem packing and backup ring (if applicable). a. Use packing sleeve P/N 21168 for 1” stem size and packing sleeve P/N 233842 for 1 ¼” stem size. 1) Thread the packing sleeve into the bonnet packing gland preparation until the sleeve bottoms out. 2) Using a grease gun attached to the bonnet grease fitting, pump the packing out into the recessed area of the packing sleeve.
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3) Remove the sleeve from the bonnet. b. If a packing sleeve is not available, remove the stem packing by one of the following methods: 1) Pump the packing out with grease until the grease byes or the packing refuses to extrude further. 2) Pull the packing out with a corkscrew. Caution: Do not damage the stem or packing bore.
B. Installation of the New Packing 1. Clean the grease from the stuffing box bore so that hydraulic lock will not prevent the installation of new packing. 2. Inspect the stuffing box to ensure that the bore is clean and free of pits or scars. 3. Inspect the stem to ensure that the surface is free of burrs and pits. 4. Apply a light coat of grease to: a. The stem. b. The stuffing box bore. c. The ID and OD of the stem packing. d. The nose and threads of the packing gland. 5. Lightly grease the new stem packing. Install it over the stem and into the bonnet as follows: a. J packing or U packing: Install with rounded nose facing pressure. b. Varipak or SLS packing: Install with open-end facing pressure. c. HT-20 packing: Call Cameron service. (Special tools required; not replaceable). 6. Using the packing gland as a pushing tool, push the packing into the stuffing box. 7. Remove the packing gland and lubricate the stem OD. If a packing back-up ring is required, install it over the stem.
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8. Install the packing gland and apply approximately 200 ft-lb (270 N•m) of torque, ensuring that the bonnet threads are not damaged. 9. Inspect the bearings and bearing races on the stem adapter for pits, scores, or cracks. Replace if damaged. 10. Pack the bearings with grease. 11. Place each bearing between a pair of carefully cleaned races. 12. Carefully clean the stem adapter. 13. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. 14. Insert the stem adapter over the end of the stem and align the pinhole in the adapter with the hole in the stem. 15. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer. 16. Replace the stem adapter O-ring if necessary. 17. Inspect the bearing cap to ensure that an extra race, held by grease tension is not retained inside. 18. Clean the bearing cap and lubricate the threads. 19. Install the cap, and torque to 200 ft-lb (270 N•m). 20. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not ing the bonnet shoulder. 21. Inject grease through the bearing cap grease fitting until the excess grease es through the bleed port. 22. Lubricate the body cavity. Refer to Part II.
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VII. Gate and Seat Replacement
A. Gate and Seat Disassembly 1. Isolate the valve from the line pressure. 2. Release the cavity pressure by bleeding the cavity pressure through the bonnet grease fitting. 3. With the bonnet grease fitting still vented, stroke the valve one complete cycle, ending in the full open position. Caution: Any trapped pressure will be vented through the bonnet grease fitting or end flange. 4. Remove all bonnet nuts. 5. the bonnet and turn the handwheel clockwise until the stem completely backs out of the gate. 6. Remove the bonnet assembly. 7. Pull the gate from the body. 8. Remove the seats. Note: If the seats are stuck, insert a screwdriver in the groove on the OD of the seat and pry the seat out. 9. Flush the body cavity thoroughly with suitable solvent and wipe clean with a rag.
B. Gate and Seat Inspection 1. Inspect the cavity parts for damage. a. Ensure that the retainer plate is not bent, twisted, or distorted. Important: Solid material should not be built up on the retainer plate surfaces. b. Ensure that the seal rings are not damaged. c. Ensure that the seats are not cut or damaged. d. Ensure that the gate is not cut or damaged. 2. Replace any damaged parts.
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3. Ensure that the body cavity is free of all foreign matter such as solid particles, grit, trash, etc. 4. Clean the body cavity with a suitable cleaning solvent. 5. Apply a thin coat of clean grease to the body cavity, gate, retainer plate, seats, and seat seal rings. 6. Install the U-shaped retainer plate in the bottom of the body cavity. The flat center part of the retainer plate goes against the cavity bottom, and the semi-circular cut-outs must be aligned with the seat pockets.
C. Gate and Seat Assembly 1. Install the seal rings into the face groove(s) located in the seats. Note: The FL valve uses one seal ring per seat; the FLS uses two per seat. 2. Install the seats into the seat pockets. Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal face. Do not apply more than a very thin film of grease to the back face of the seat and seal ring(s) or the seal face on the body seat pocket. 3. Install the gate into the cavity between the seats. 4. Push the gate all the way to the bottom of the cavity and pack the remaining space with grease. 5. Remove the seal ring from the bonnet groove. 6. Clean the grooves and/or seating area of the body and bonnet. 7. Apply a very thin film of clean grease to the bonnet seal ring and groove. 8. Install the new seal ring in the bonnet groove. 9. Install the bonnet over the body studs. a. On valves 5000 psi WP and below, rotate the bonnet so that the bonnet locating pins in the body align with the pinholes in the bonnet. b. On valves 10,000 psi WP and above, rotate the bonnet until the grease fitting is 90° from the gate bore. 10. Thread the stem into the gate by turning the handwheel counterclockwise. TC148
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11. Pull the bonnet down over the studs. 12. Hand tighten the bonnet nuts. 13. Ensure that the gate is not on the bottom of the cavity. 14. Evenly tighten the bonnet nuts. (See Table Below.) Note: The raised bonnet face on valves 10,000 psi and above will fully the body face when the bonnet nuts are tight.
Bolt Size Nom OD - TPI .625-11 .750-10 .875-9 1.000-8 1.125-8 1.250-8 1.375-8 1.500-8 1.625-8
Bolt Size Nom OD - TPI .625-11 .750-10 .875-9 1.000-8 1.125-8 1.250-8 1.375-8 1.500-8 1.625-8
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Recommended Makeup Torques, Ft-Lbf Per API 6A: Preload = .50Sy English Units B7M, L7M (80 ksi) B7, L7, 660 (105 ksi) Xylan or Xylan or Zinc Plated Zinc Plated Sermagard Sermagard or Uncoated or Uncoated Coated Coated 52 90 143 213 305 421 563 733 934
88 153 243 361 523 726 976 1280 1640
68 118 188 279 401 553 739 962 1230
115 200 319 474 686 953 1280 1680 2150
Recommended Makeup Torques, N•m Per API 6A: Preload = .50Sy Metric Units B7M, L7M (80 ksi) B7, L7, 660 (105 ksi) Xylan or Xylan or Zinc Plated Zinc Plated Sermagard Sermagard or Uncoated or Uncoated Coated Coated 70 122 193 288 413 569 761 991 1260
118 206 328 488 706 981 1320 1730 2210
25
92 160 253 376 540 745 996 1300 1660
155 270 429 639 925 1290 1730 2270 2910
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VIII. Ordering Replacement Parts The only information needed for ordering replacement parts for a Cameron gate valve is the original valve assembly part number and the description of the part. The valve assembly part number is stamped on the valve body nameplate. It is recommended that a description of the valve assembly (size, pressure, trim) be included as a check on the assembly number, but this is not necessary if the assembly number is clearly readable. It is not recommended to order replacement parts by using the part number off the old part or by referring to a file copy of the valve assembly bill-of-material. If an engineering change has been implemented to the valve assembly to replace one component part number with another, the only way to ensure getting the updated component is to reference the valve assembly number and to reference the part by description (gate, seat, stem, etc. Part descrip-
tions are shown in the parts list, Part I.D.). Cameron personnel can then check the latest revision of the assembly bill-of-material to obtain the appropriate and current replacement part number. The replacement parts list included in this manual contain part numbers for Cameron FL manual and surface actuated failsafe gate valves manufactured prior to API 6A 15th Edition (1986), operating in the temperature ranges between -20 and 250oF (-29 and 121o C). your Cameron representative for replacement parts for FLS and all other FL gate valves.
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Figure 1 FL MANUAL GATE VALVE ALL EXCEPT 3-1/16 15,000 PSI WP
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FIGURE 2 FL MANUAL GATE VALVE 3-1/16 15,000 PSI WP
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FIGURE 3 FL GATE VALVE PREPPED FOR ACTUATOR ALL SIZES AND PRESSURES
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Manually Actuated Cameron FL and FLS Gate Valves
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All the information in this manual is the exclusive property of Cameron International Corporation. Any reproduction or use of the calculations, drawings, photographs, procedures, or instructions, either expressed or implied, is forbidden without the expressed written permission of Cameron or its authorized agent.
Initial Release A1 April 1992 Revision B1 April 1994 Revision C1 June 1997 Revision D1 June 2005 Revision E1 February 2007 Revision F1 March 2008
Copyright © 2008 all rights reserved by Cameron International Corporation
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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 or injury 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 Cameron products, which are products of Cameron International Corporation. Cameron P.O. Box 1212 Houston, Texas 77251-1212 713-939-2211 http://www.c-a-m.com
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Table Of Contents I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Description and Features . B. Operation Instructions . . C. Dimensional Data . . . . . D. Parts List . . . . . . . . . .
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II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A. Lubrication . . . . . . . . . B. Lubrication Charts . . . . . . C. Body Cavity Lubrication . . . D. Thrust Bearing Lubrication .
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III. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IV. Bonnet Grease Fitting Replacement . . . . . . . . . . . . . . . . . . 15 A. Valves 10,000 psi and Below . . . . . . . . . . . . . . . . . . . 15 B. Valves 15,000 psi and Above . . . . . . . . . . . . . . . . . . . 16 V. Stem Pin and Thrust Bearing Replacement . . . . . . . . . . . . . . . 17 A. Removal of the Thrust Bearings . . . . . . . . . . . . . . . . . 17 B. Installation of the New Thrust Bearings . . . . . . . . . . . . . 18 VI. Stem Packing Replacement With Pressure In The Valve . . . . . . . 19 A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . 19 B. Installation of the New Packing . . . . . . . . . . . . . . . . . 21 VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . 23 A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . 23 B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . 23 C. Gate and Seat Assembly . . . . . . . . . . . . . . . . . . . . . 24 VIII. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . 27
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I. General Information
A. Description and Features The FL or FLS gate valve is a full-bore through-conduit valve designed and manufactured in accordance with ISO 10423, API 6A, and NACE MR-01-75. It is available in standard double flange, threaded-end, and special block body configurations. The following are standard features of the FL and FLS gate valves: 1. Sealing at the gate-to-seat and the seat-to-body is metal-to-metal. 2. The simplified gate and seat assembly has a minimum number of parts. One-piece seats and slab gate ensure reliable sealing and simplify field service. The modified Acme gate-to-stem thread allows the gate to move back and forth, or float, to seal against the seat. 3. The gate and seat assembly seals in both directions, and the gate and seats can be reversed for increased life. 4. The stem shoulder can be back seated against the bonnet to isolate the stuffing box, which allows field-replacement of the stem packing while the valve is under pressure. 5. The non-rising stem prevents a cavity pressure increase or displacement of cavity lubricant. 6. All FL and FLS valves have a specially designed, metal-to-metal sealing grease fitting which contains a check valve. The stem, gate, and seat are lubricated through the grease fitting which is located on the downstream side of the stem backseat for safety. No sealant or lubricant ports extend directly into the valve cavity. 7. The seal between the valve body and bonnet is a pressure-energized, BX-style metal bonnet gasket on 10,000 and 15,000 psi WP valves. Valves for 3000 and 5000 psi WP use a flat compression-type metal gasket. 8. API 6A Materials Classes and Temperature Classes are available, and other special trims area available upon request. Reduced-hardness bonnet bolting can be supplied for most sizes and pressures without downrating the working pressure. 9. With minor modifications, FLS valves can meet or exceed API 6FA fire safety requirements.
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10. Special non-elastomeric stem packing designs can extend the standard temperature rating of the FL or FLS Gate Valve up to 350o F (180oC), or down to -75o F (-60oC). These temperature ratings may not be available in all working pressures. 11. An optional add-on torque multiplier is available for larger FL and FLS valves to provide easier operation. 12. See the valve assembly bill-of materials for materials and descriptions of valve components.
B. Operation Instructions A gate valve should always be in either the full-open or full-closed position. Leaving the gate partially open or throttling through the valve could cause damage to the gate. The valve is opened by turning the handwheel counterclockwise (to the left) until it stops. Turning the handwheel back to the right ¼ turn will then relieve any stress in the stem, and is, therefore, recommended practice. Initial torque required to open the valve is given in Table I. The valve is closed by turning the handwheel clockwise (to the right) until it stops, and then backing off (counterclockwise) ½ to ¾ turn. The number of turns required to move the valve from full open to full closed is given in Table I. Table I: Operating Requirements 2000 - 3000 psi WP
5000 psi WP
Valve Bore Size -
2-1/16
2-9/16
3-1/8
4-1/16
5-1/8
6-3/8
2-1/16
2-9/16
3-1/8
4-1/16
5-1/8
6-3/8
Expected Opening Torque, Lubricated Valve, ft-lb
15
20
25
30
45
80
20
25
35
50
75
140
Maximum Opening Torque, Severe Service, ft-lb
30
40
60
80
130
235
45
65
95
135
220
395
Total Number of Turns, Full-Open to Full-Close
12-1/3
15-1/8
18-1/8
23-1/4
27-1/2
33-3/4
12-1/3
15-1/8
18-1/8
23-1/4
27-1/2
33-3/4
Valve Bore Size - Inch
1-13/16
2-1/16
2-9/16
3-1/16
4-1/16
5-1/8
1-13/16
2-1/16
2-9/16
3-1/16
Expected Opening Torque, Lubricated Valve, ft-lb
30
35
50
65
110
260*
50
60
100
125
Maximum Opening Torque, Severe Service, ft-lb
80
85
130
170
320
690*
125
155
265
335
12-1/3
12-1/3
15-1/8
18-1/8
23-1/4
29
12-1/3
12-1/3
15-3/4
22-7/8
Inch
10,000 psi WP
Total Number of Turns, Full-Open to Full-Close
15,000 psi WP
* Optional torque multiplier recommended. See manual #SD-1792.
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C. Dimensional Data
Table II: Dimensional Data - 2000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
6-1/8”
End-to-End, Flanged (Ring t)
11-5/8”
13-1/8”
14-1/8”
17-1/8”
22-1/8”
B
Extreme Width of Body
6-1/8”
7-1/8”
7-3/4”
9-3/4”
12-3/8”
C
Center of Port to Top of Stem Adapter
13”
33-13/16”
16-13/16”
18-7/16”
22-3/4”
D
Center of Port to Bottom of Body
5-1/4”
6”
7-1/8”
9-1/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
15-3/8”
16-1/8”
19-1/16”
20-11/16”
24”
F
Handwheel OD
14”
14”
14”
14”
18-1/2”
160 lb
200 lb
240 lb
350 lb
800 lb
A
Description
Weight (Flanged)
Table III: Dimensional Data - 3000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8"
A
End-to-End, Threaded
Description
10-5/8 ”
12-3/8”
13-5/8”
—
—
—
A
End-to-End, Flanged (Ring t)
14-5/8"
16-5/8"
17-1/8"
20-1/8”
24-1/8”
24-1/8”
B
Extreme Width of Body
6-3/4”
7-5/8 ”
7-1/2”
10-1/2”
21”
12-3/4”
C
Center of Port to Top of Stem Adapter
13”
33-13/16”
16-13/16”
18-7/16”
21-5/16"
22-3/4”
D
Center of Port to Bottom of Body
5-5/8”
6-1/2”
7-3/8”
9-1/8”
11-3/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
15-3/8”
16-1/8”
19-1/16”
20-11/16”
22-9/16”
24”
F
Handwheel OD Weight (Flanged)
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6-1/8”
14”
14”
14”
18-1/2”
24”
24”
170 lb
220 lb
260 lb
450 lb
750 lb
1000 lb
9
Table IV: Dimensional Data - 5000 psi WP Item
2-1/16”
2-9/16”
3-1/8”
4-1/8”
5-1/8"
6-1/8”
A
End-to-End, Threaded
Description
10-5/8 ”
12-3/8”
13-5/8 ”
—
—
—
A
End-to-End, Flanged (Ring t)
14 -5/8"
16 -5/8"
18 -5/8”
21-5/8 ”
28-5/8 ”
29”
A
End-to-End, Butt Weld
—
—
—
21-1/2”
—
—
B
Extreme Width of Body
7”
8-3/16”
9-1/4”
10-13/16”
21-3/4”
14-1/8”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-15/16”
16-13/16”
18-7/16”
21-5/16"
22-3/4”
D
Center of Port to Bottom of Body
5-5/8”
6-1/2”
7-3/8”
9-1/8”
11-3/8”
12-7/8”
E
Center of Port to Top of Handwheel Rim
17-3/8”
18-1/8”
19-1/16”
20-11/16”
23-9/16”
24”
F
Handwheel OD
14”
14”
18-1/2”
18-1/2”
24”
24”
175 lb
230 lb
360 lb
520 lb
800 lb
1160 lb
Weight (Flanged)
Table V: Dimensional Data - 10,000 psi WP Item
1-13/16”
2-1/16”
2-9/16”
3-1/16”
4-1/16”
5-1/8”
A
End-to-End, Flanged (Ring t)
Description
18-1/4”
20-1/2”
22-1/4”
24-3/8”
26-3/8”
29”
B
Extreme Width of Body
9-1/16”
9-3/8”
9-13/16”
10-1/4”
12-13/16”
23-1/2”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-1/8”
15-13/16”
16-7/8”
19-11/16”
23-7/8”
D
Center of Port to Bottom of Body
5-3/4”
5-7/8”
6-13/16”
8-1/16”
10-1/16”
13-1/8”
E
Center of Port to Top of Handwheel Rim
17-3/8”
17-3/8”
18-1/8”
18-1/16”
20-15/16”
25-1/4”
F
Handwheel OD
14”
18-1/2”
18-1/2”
24”
24”
24”
250 lb
275 lb
370 lb
480 lb
880 lb
1750 lb
Weight (Flanged)
Table VI: Dimensional Data - 15,000 psi WP Item
Description
A
End-to-End, Flanged (Ring t)
B
1-13/16”
2-1/16”
2-9/16”
3-1/16”
18”
19”
21”
23-9/16”
Extreme Width of Body
9-7/8”
9-7/8”
11-1/2”
13-9/16”
C
Center of Port to Top of Stem Adapter
15-1/8”
15-1/8”
17-3/16”
20-15/16”
D
Center of Port to Bottom of Body
5-7/8”
6-1/8”
7-5/16”
9-1/4”
E
Center of Port to Top of Handwheel Rim
17-3/8”
17-3/8”
19-9/16”
22-3/16”
F
Handwheel OD
18-1/2”
18-1/2”
18-1/2”
24”
Weight
275 lb
300 lb
560 lb
890 lb
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D. Parts List
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II. Periodic Maintenance A. Lubrication 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
+250o F. b. For continuous service below 0° F, use one of the two available low temperature greases. c. For continuous service above 180o F, use one of the two available high temperature greases. d. Part numbers for ordering grease as well as selection guidelines are given in Table VIII. 2. Recommended stem bearing lubricant. a. For normal operation, use Cameron standard valve lubricant, which is not affected by water or temperatures ranging from -20o to
+250o F. b. For continuous service below 0° F, use one of the two available low temperature greases.
B. Lubrication Charts Table VII: Grease Volume Requirements Bore Size (in.)
Pressure Rating
Lubricant Volume
Lubricant Weight
Approximate Follower
Required (cu in.)
(lb)
Plate Travel (in.)
1-13/16"
2-9/16"
All All To 10,000 15,000
3-1/8”
To 5000
3-1/16”
10,000
3-1/16”
15,000
4-1/8”
To 5000
4-1/16”
10,000
38 43 79 93 114 114 155 245 243 312 461 583 583
1.5 1.7 3.2 3.7 4.6 4.6 6.2 9.8 9.7 12.5 18.5 23.3 23.3
.5 .7 1.3 1.6 1.9 1.9 2.6 4.2 4.1 5.3 7.8 9.9 9.9
2-1/16” 2-9/16"
5-1/8”
5000
5-1/8”
10,000
6-1/8”
To 5000
6-3/8”
To 5000
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Table VIII: Lubricant Selection
With H2S
With High C02
(Per Pound)
5 lb Can
25 lb Pail
120 lb Drum
400 lb Drum
-20oF to 250oF (-29oC to 121oC) -50oF to 250oF (-46oC to 121oC) Low Temp -75oF to 350oF (-59oC to 177oC) Diesel -0oF to 350oF Resistant (-18oC to 177oC) -0ooF to 450ooF (-18 C to 232 C) High o Temp -20 F to 500oF (-29oC to 260oC) E - Excellent (Recommended) G - Good (Recommended) Standard
Quantities (By Part Number) Available on a Standard Order Basis
Operational Properties
Diesel
Service Temperature
Standard Crude
Service
E
P
F
P
700149
700667
70668*
700669
700670
E
P
F
P
700123
700671
700672
700673
700674
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
G
P
F
P
700217
700679
700680
700681
700682
G
P
F
P
710194
710194-1
710194-2
710194-3
710194-4
F - Fair (Not Recommended) P - Poor (Not Recommended)
*Available in 20 lb pail only
C. Body Cavity Lubrication 1. Normal Operating Conditions Note: Cameron lubricates gate valves on assembly. Lubricate the body cavity after ten operating cycles. One cycle equals opening and closing the valve one time. The service interval can vary according to application, fluids used, and well conditions. If pressure is equalized across the valve before the valve is opened, the service interval can be extended. If the valve is removed from service, lubricate the body cavity before returning it to the line. a. Remove the grease-fitting cap located on the bonnet flange OD. b. Using either a bucket-type gun, P/N 19873-03, or hand-held type, P/N 19873-01, connect the grease gun coupler to the grease fitting. c. Pump the appropriate amount of lubricant into the body cavity. Refer to Part II, Paragraph B.
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2. Unusual Temporary Operating Conditions If it becomes necessary to cement through, acidize through, or subject the valve to any other unusual service, proceed as follows: a. Lubricate the valve body cavity before it is put into operation. b. Flush the valve with the appropriate neutralizing fluid in the line. c. Operate the valve with fresh water or appropriate neutralizing fluid in the line. d. Lubricate the valve body cavity.
D. Thrust Bearing Lubrication Note: Lubricate the thrust bearings as often as required to ensure smooth valve operation. 1. Using a hand-held grease gun, P/N 19873-01, connect the grease gun fitting to the hydraulic grease fittings with a hydraulic coupler. 2. Pump lubricant into the fittings until clean grease appears at the bleed port on the opposite side of the bearing cap.
III. Troubleshooting Symptom Fluid leaks past the gate and seat assembly.
1. Gate or seats are worn. 2. Handwheel is not backed off.
Action 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.
1. Bonnet seal ring is worn. 2. Bonnet or body ring groove oois damaged. Check valve inside the grease fitting is worn.
Replace the bonnet seal ring. Return the valve to Cameron for repair. Replace the grease fitting.
1. Thrust bearings have lost oolubricant.
Lubricate the thrust bearings.
2. Thrust bearings are corroded. 3. Gate and stem threads have oolost lubricant.
Replace the thrust bearings. Lubricate the gate and stem through the bonnet grease fitting.
Stem pin is sheared.
Replace the stem pin.
Fluid leaks at the bonnet flange. Fluid leaks from the bonnet grease fitting.
Handwheel is hard to turn.
Handwheel turns without opening or closing the valve.
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Caution: When a valve is used in the lower master valve position, on the outlet of a BOP or any other application in which it is the last surface barrier, precautions should be taken to ensure sub-surface safety barriers are in place and functioning. If valve bonnet maintenance is to be performed such as stem packaging replacement, bearing replacement or stem pin replacement consideration should be given with respect to number of barriers required by the customer and the local statutory requirements.
IV. Bonnet Grease Fitting Replacement
A. Valves 10,000 psi WP and Below 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 3. a. Remove the grease fitting cap. b. Trip the ball in the grease fitting check valve by inserting a 1/8” diameter by ¾” long pin into the run of the fitting. c. Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released. d. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. e. If pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. TC148
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2) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the grease fitting from the valve bonnet. 4. Install a new grease fitting. Caution: Installing the fitting with the cap in place could damage the cap. Do not install the fitting with the cap in place. 5. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb (33 N•m). b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap.
c. Tighten the bearing cap to approximately 200 ft-lb (270 N•m).
B. Valves 15,000 psi WP and Above Note: The standard grease fitting for 15,000 psi WP FL valves is a special metal-sealing, high pressure fitting, containing a check valve. The bonnet port housing this fitting is a special preparation without pipe threads which accepts only this type of fitting. Important: DO NOT use Teflon tape or thread sealant on these fittings. 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 4. TC148
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a. Remove the grease fitting cap. b. Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. c. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. d. If pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. 2) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the grease fitting from the valve bonnet. 4. Remove the cap from a new grease fitting and install the fitting in the bonnet. Torque to 80 to 100 ft-lb (100 to 135 N•m). 5. Install and tighten the cap on the fitting. Caution: Installing the fitting with the cap in place prevents the fitting from seating and could cause damage to the cap. Do not install the fitting with the cap in place. 6. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb (33 N•m). b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap. c. Tighten the bearing cap to approximately 200 ft-lb (270 N•m).
V. Stem Pin and Thrust Bearing Replacement Note: The stem thrust bearings can be replaced while the valve is under pressure in the line.
A. Removal of the Thrust Bearings 1. Loosen the bearing cap, using a 24” pipe wrench. After two or three turns, the cap will rotate freely by hand.
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Caution: If the cap does not rotate freely after three turns, the packing gland may be moving outward with the bearing cap. This can be checked by tapping on the stem adaptor so it moves relative to the bearing cap. If the stem adaptor does not move inward or continues to back out with the bearing cap, DO NOT remove the cap. Tighten the cap and a Cameron representative. 2. If the bearing cap rotates freely, remove the cap from the bonnet. 3. Using a punch, drive the stem pin from the stem adapter, ensuring that the adapter is not damaged. 4. Remove the adapter from the stem. Remove both sets of bearings and bearing races from the stem adapter. 5. Discard any pitted, cracked, or damaged bearings or races. 6. Replace the stem adapter if either of the bearing surfaces on the adapter shoulder is damaged.
B. Installation of the New Thrust Bearings. 1. Remove the new bearings from the protective packaging. 2. Pack the bearings with clean grease. 3. Place each bearing between a pair of carefully cleaned races. 4. Carefully clean the stem adapter. 5. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. 6. Insert the stem adapter over the end of the stem and align the pin hole in the adapter with the hole in the stem. 7. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer. 8. Replace the stem adapter O-ring if necessary. 9. Inspect the bearing cap to ensure that an extra race, held by grease tension, is not retained inside. TC148
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10. Clean the bearing cap and lubricate the threads. 11. Install the cap, and tighten to approximately 200 ft-lb (270 N•m). 12. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not ing the bonnet shoulder. 13. Inject grease through the bearing cap grease fittings until the excess grease es through the bleed port.
VI. Stem Packing Replacement with Pressure in the Valve
A. Removal of the Stem Packing 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly s the bottom of the cavity and the stem moves outward, ing the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Backseat the valve. a. Valves 10,000 psi WP and Below. Refer to Figure 3. 1) Remove the bonnet grease fitting cap. 2) Trip the ball in the grease fitting check valve by inserting an 1/8” diameter by ¾” long pin into the run of the fitting. 3) Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped b the backseating process is released. 4) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 5) If pressure continues to escape, the backseat in ineffective. a) Backseat the valve again. Repeat steps 1 and 2.
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b) If the backseat continues to be ineffective, a Cameron representative. b. Valves 15,000 psi WP and Above. Refer to Figure 4. 1) Remove the grease fitting cap. 2) Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. 3) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 4) If pressure continues to escape, the backseat in ineffective. a) Backseat the valve again. Repeat steps 1 and 2. b) If the backseat continues to be ineffective, a Cameron representative. 3. Remove the handwheel and bearing cap. 4. Remove the cap from the bonnet. 5. Using a punch, drive the stem pin from the stem adapter, ensuring that the adapter is not damaged. 6. Remove the adapter from the stem. 7. Remove both sets of bearings and bearing races from the stem adapter. 8. Loosen the packing gland. 9. Ensure that the threads on the bonnet neck OD are not damaged. 10. Remove the packing gland. 11. Remove the stem packing and backup ring (if applicable). a. Use packing sleeve P/N 21168 for 1” stem size and packing sleeve P/N 233842 for 1 ¼” stem size. 1) Thread the packing sleeve into the bonnet packing gland preparation until the sleeve bottoms out. 2) Using a grease gun attached to the bonnet grease fitting, pump the packing out into the recessed area of the packing sleeve.
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3) Remove the sleeve from the bonnet. b. If a packing sleeve is not available, remove the stem packing by one of the following methods: 1) Pump the packing out with grease until the grease byes or the packing refuses to extrude further. 2) Pull the packing out with a corkscrew. Caution: Do not damage the stem or packing bore.
B. Installation of the New Packing 1. Clean the grease from the stuffing box bore so that hydraulic lock will not prevent the installation of new packing. 2. Inspect the stuffing box to ensure that the bore is clean and free of pits or scars. 3. Inspect the stem to ensure that the surface is free of burrs and pits. 4. Apply a light coat of grease to: a. The stem. b. The stuffing box bore. c. The ID and OD of the stem packing. d. The nose and threads of the packing gland. 5. Lightly grease the new stem packing. Install it over the stem and into the bonnet as follows: a. J packing or U packing: Install with rounded nose facing pressure. b. Varipak or SLS packing: Install with open-end facing pressure. c. HT-20 packing: Call Cameron service. (Special tools required; not replaceable). 6. Using the packing gland as a pushing tool, push the packing into the stuffing box. 7. Remove the packing gland and lubricate the stem OD. If a packing back-up ring is required, install it over the stem.
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8. Install the packing gland and apply approximately 200 ft-lb (270 N•m) of torque, ensuring that the bonnet threads are not damaged. 9. Inspect the bearings and bearing races on the stem adapter for pits, scores, or cracks. Replace if damaged. 10. Pack the bearings with grease. 11. Place each bearing between a pair of carefully cleaned races. 12. Carefully clean the stem adapter. 13. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. 14. Insert the stem adapter over the end of the stem and align the pinhole in the adapter with the hole in the stem. 15. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer. 16. Replace the stem adapter O-ring if necessary. 17. Inspect the bearing cap to ensure that an extra race, held by grease tension is not retained inside. 18. Clean the bearing cap and lubricate the threads. 19. Install the cap, and torque to 200 ft-lb (270 N•m). 20. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not ing the bonnet shoulder. 21. Inject grease through the bearing cap grease fitting until the excess grease es through the bleed port. 22. Lubricate the body cavity. Refer to Part II.
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VII. Gate and Seat Replacement
A. Gate and Seat Disassembly 1. Isolate the valve from the line pressure. 2. Release the cavity pressure by bleeding the cavity pressure through the bonnet grease fitting. 3. With the bonnet grease fitting still vented, stroke the valve one complete cycle, ending in the full open position. Caution: Any trapped pressure will be vented through the bonnet grease fitting or end flange. 4. Remove all bonnet nuts. 5. the bonnet and turn the handwheel clockwise until the stem completely backs out of the gate. 6. Remove the bonnet assembly. 7. Pull the gate from the body. 8. Remove the seats. Note: If the seats are stuck, insert a screwdriver in the groove on the OD of the seat and pry the seat out. 9. Flush the body cavity thoroughly with suitable solvent and wipe clean with a rag.
B. Gate and Seat Inspection 1. Inspect the cavity parts for damage. a. Ensure that the retainer plate is not bent, twisted, or distorted. Important: Solid material should not be built up on the retainer plate surfaces. b. Ensure that the seal rings are not damaged. c. Ensure that the seats are not cut or damaged. d. Ensure that the gate is not cut or damaged. 2. Replace any damaged parts.
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3. Ensure that the body cavity is free of all foreign matter such as solid particles, grit, trash, etc. 4. Clean the body cavity with a suitable cleaning solvent. 5. Apply a thin coat of clean grease to the body cavity, gate, retainer plate, seats, and seat seal rings. 6. Install the U-shaped retainer plate in the bottom of the body cavity. The flat center part of the retainer plate goes against the cavity bottom, and the semi-circular cut-outs must be aligned with the seat pockets.
C. Gate and Seat Assembly 1. Install the seal rings into the face groove(s) located in the seats. Note: The FL valve uses one seal ring per seat; the FLS uses two per seat. 2. Install the seats into the seat pockets. Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal face. Do not apply more than a very thin film of grease to the back face of the seat and seal ring(s) or the seal face on the body seat pocket. 3. Install the gate into the cavity between the seats. 4. Push the gate all the way to the bottom of the cavity and pack the remaining space with grease. 5. Remove the seal ring from the bonnet groove. 6. Clean the grooves and/or seating area of the body and bonnet. 7. Apply a very thin film of clean grease to the bonnet seal ring and groove. 8. Install the new seal ring in the bonnet groove. 9. Install the bonnet over the body studs. a. On valves 5000 psi WP and below, rotate the bonnet so that the bonnet locating pins in the body align with the pinholes in the bonnet. b. On valves 10,000 psi WP and above, rotate the bonnet until the grease fitting is 90° from the gate bore. 10. Thread the stem into the gate by turning the handwheel counterclockwise. TC148
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11. Pull the bonnet down over the studs. 12. Hand tighten the bonnet nuts. 13. Ensure that the gate is not on the bottom of the cavity. 14. Evenly tighten the bonnet nuts. (See Table Below.) Note: The raised bonnet face on valves 10,000 psi and above will fully the body face when the bonnet nuts are tight.
Bolt Size Nom OD - TPI .625-11 .750-10 .875-9 1.000-8 1.125-8 1.250-8 1.375-8 1.500-8 1.625-8
Bolt Size Nom OD - TPI .625-11 .750-10 .875-9 1.000-8 1.125-8 1.250-8 1.375-8 1.500-8 1.625-8
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Recommended Makeup Torques, Ft-Lbf Per API 6A: Preload = .50Sy English Units B7M, L7M (80 ksi) B7, L7, 660 (105 ksi) Xylan or Xylan or Zinc Plated Zinc Plated Sermagard Sermagard or Uncoated or Uncoated Coated Coated 52 90 143 213 305 421 563 733 934
88 153 243 361 523 726 976 1280 1640
68 118 188 279 401 553 739 962 1230
115 200 319 474 686 953 1280 1680 2150
Recommended Makeup Torques, N•m Per API 6A: Preload = .50Sy Metric Units B7M, L7M (80 ksi) B7, L7, 660 (105 ksi) Xylan or Xylan or Zinc Plated Zinc Plated Sermagard Sermagard or Uncoated or Uncoated Coated Coated 70 122 193 288 413 569 761 991 1260
118 206 328 488 706 981 1320 1730 2210
25
92 160 253 376 540 745 996 1300 1660
155 270 429 639 925 1290 1730 2270 2910
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VIII. Ordering Replacement Parts The only information needed for ordering replacement parts for a Cameron gate valve is the original valve assembly part number and the description of the part. The valve assembly part number is stamped on the valve body nameplate. It is recommended that a description of the valve assembly (size, pressure, trim) be included as a check on the assembly number, but this is not necessary if the assembly number is clearly readable. It is not recommended to order replacement parts by using the part number off the old part or by referring to a file copy of the valve assembly bill-of-material. If an engineering change has been implemented to the valve assembly to replace one component part number with another, the only way to ensure getting the updated component is to reference the valve assembly number and to reference the part by description (gate, seat, stem, etc. Part descrip-
tions are shown in the parts list, Part I.D.). Cameron personnel can then check the latest revision of the assembly bill-of-material to obtain the appropriate and current replacement part number. The replacement parts list included in this manual contain part numbers for Cameron FL manual and surface actuated failsafe gate valves manufactured prior to API 6A 15th Edition (1986), operating in the temperature ranges between -20 and 250oF (-29 and 121o C). your Cameron representative for replacement parts for FLS and all other FL gate valves.
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Figure 1 FL MANUAL GATE VALVE ALL EXCEPT 3-1/16 15,000 PSI WP
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FIGURE 2 FL MANUAL GATE VALVE 3-1/16 15,000 PSI WP
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FIGURE 3 FL GATE VALVE PREPPED FOR ACTUATOR ALL SIZES AND PRESSURES
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