Cameron Gate Valves

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Manually Actuated FLS-TC

Fire Resistant Gate Valves

with Heat Sensitive Backseating Feature

Operation and Maintenance Manual

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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 instruc-tions, either expressed or implied, is forbidden without the written per-mission of Cameron or its authorized agent.

Initial Release A1

November 1998

Cooper Cameron Corporation Cameron Division

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PREFACE

The procedures included in this book are to be performed in conjunc-tion with the requirements and recommendaconjunc-tions outlined in API Speci-fications. 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 re-sulting in whole or in part from repairs performed by other than author-ized Cameron personnel. Such unauthorauthor-ized 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 require-ments.

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

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Table II: Dimensional Data - English Units Nominal Size (in) Working Pressure (psi) Dimensions (in) Weight (lb) Number of Turns A B C D E F 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 ( ) = Approximate Dimension

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Dimensional Data Figure 1 _SD016774 End View Side View B C 3.75" (95.25 mm) F E D A

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Table II: Dimensional Data - Metric Units Nominal Size (in) Working Pressure (psi) Dimensions (mm) Weight (kg) Number of Turns A B C D E F 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 ( ) = Approximate Dimension

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D. Assembly Drawings and Parts Lists 23 15,000 PSI WP 2000 Thru 5000 psi WP 4 10,000 & 24 2000 Thru 5000 psi WP

(Shown 90° out of Position) 26 25 24 34 32 31 30 29 28 27 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 3 2 1 SD017018 TC2FLS5K.DWG Figure 2

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Parts List: FLS-TC Manual Gate Valve, Figure 2

Item Recommended

Spare Part Description

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 * Bearing Race 12 Grease Fitting 13 * 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 * 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

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Optional 41 25 33 27 26 28 32 31 40 7

(Shown 90° out of Position) 7 24 18 38 37 36 35 34 30 29 22 21 20 17 16 15 14 13 12 11 10 9 8 23 19 6 5 4 3 2 1 SD017017 TC56.DWG Figure 3

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Parts List: FLS-TC Manual Gate Valve, Figure 3

Item Spare_Part Description Item Spare

Part Description

1 Stem Adapter 22 * Stem Seal

2 * Pin (Shear) 23 Heat Shield (Optional)

3 Collar 24 * Grease Fitting

4 * Grease Fitting 25 * Check Valve (Optional)

5 Bearing Cap 26 Stem

6 Bearing Mount 27 Bonnet

7 Spring 28 * Gate

8 Retainer Ring 29 Stud

9 * O-Ring 30 Nut

10 * Lip Seal 31 Hex Head Cap Screw

11 * Ball Bearing 32 * Gasket

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 * O-Ring 40 Hand Wheel

20 Support ring 41 * Wear Ring

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30 29 28 27 26 25

Shown 90° out of Position 24

23 22 21 18 17 16 20 19 34 33 15 14 13 12 11 10 7 6 9 4 3 5 8 2 1 32 Figure 4 SD017016 TC29SRL.DWG

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Parts List: FLS-TC Manual Gate Valve, Figure 4

Item Recommended

Spare Part Description

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 * Bearing Race 12 Grease Fitting 13 * 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 * 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

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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 CO2injection or very high CO2production, 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.

Table III: Lubricant Selection

Service Service Temperature

Operational Properties

Quantities (By Part Number) Available on a Standard Order Basis

Standard Crude Diesel With H2 S With High CO 2 (Per Pound) 5l bC a n 25 lb Pail 120 lb Drum 400 lb Drum Standard -20°F to 250°F (-29°C to 121°C) E P F P 700149 700667 700668* 700669 700670 Low Temperature -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 Diesel Resistant -0°F to 350°F (-18°C to 177°C) E E G G 713837 713837-1 713837-2 713837-3 713837-4 High Temperature -0°F to 450°F (-18°C to 232°C) G P F P 700217 700679 700680 700681 700682 -20°F to 500°F (-29°C to 260°C) G P F P 710194 710194-1 710194-2 710194-3 710194-4 E - Excellent (Recommended) F - Fair (Not Recommended) *Available in 20 lb pail only G - Good (Recommended) P - Poor (Not Recommended)

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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, lubri-cate 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

re-moved from service.

c. Operate the valve with fresh water or appropriate neutralizing fluid in the line.

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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. Return the valve to Cameron for repair.

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. Lubricate the gate and stem through the bonnet grease fitting.

Handwheel turns without opening or closing the valve.

Stem shear pin is sheared. Replace the stem shear pin.

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 name-plate. It is recommended that a description of the valve assembly (size, pres-sure, 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 assem-bly to replace one component part number with another, the only way to en-sure 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

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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 sub-jected 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 serv-iced.

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 Fig-ure 3. Item numbers in parentheses refer to FigFig-ure 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 sub-jected to operating torque only. The pin through the bearing mount (6) and stem (26) locks the bearing mount position on the stem.

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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.

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 ser-viced.

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 per-form 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.

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.

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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 Fig-ure 3. Item numbers in parentheses refer to FigFig-ure 3.

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 re-move 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 de-scribed 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) – turncounterclockwise (to the left) four complete turns.

c. Turn the handwheelclockwise (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

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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) – turncounterclockwise (to the left) four complete turns.

c. Turn the handwheelclockwise (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 Fig-ure 5.

Note: As an option, the high

pres-sure fitting (Refer to Sec-tion VII.B.) may be utilized in a valve rated at 10,000 psi (69 Mpa) and below.

1. Remove the grease fitting cap.

2. Unseat the ball in the grease fitting check valve by inserting a .125” (3.1 mm) di-ameter by .75” (19 mm) long pin into the run of the fitting.

3. Replace the cap slowly until the check valve ball in the fitting is un-seated, 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 Bonnet Pressure

Grease Fitting Body

Bleed By Pressure Cap Fitting Grease 1/8" Diameter Pin Bonnet

SD-10268-99

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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

pres-sure grease fitting is a special metal sealing fit-ting containing a check valve. The bonnet port is a special configuration with a straight thread, rather than a pipe thread, which accepts only this fit-ting 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 seal-ant on these fittings.

1. Remove the grease fitting cap.

2. Loosen the fitting approximately one turn (counterclockwise rotation) to unseat the metal seal, releasing pressure trapped by the backseat-ing process.

Figure 6 - High Pressure Grease Fitting

SD-10267-99 Hex Bleed By Pressure Cap Fitting Grease Bonnet

Grease Fitting Gland In Bonnet

Pressure Body Fitting Grease

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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 per-haps 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 us-ing a special Cameron unseatus-ing 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 pres-sure 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 back-seat. However, the buried check valve is apparently defective (leak-ing).

a) Remove the buried check valve unseating tool and replace the bur-ied check valve.

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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 bear-ing 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 re-place 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 num-ber for the specific valve.

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) counterclock-wise (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 re-place 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 num-ber for the specific valve.

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 With-out 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 con-tact 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 con-tact 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 re-tainer 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

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IX. BONNET GREASE FITTING REPLACEMENT

A. For Valves Rated 10,000 psi (69 Mpa) WP and Below. Item numbers in

pa-rentheses 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

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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

re-placement 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 counter-clockwise (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 po-sitioned 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 ex-cessive 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 re-quired 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.

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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 bear-ing between two races and place over the end of the bearbear-ing 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 bear-ing 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 mountclockwise (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 mountcounterclockwise (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.

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

re-placement 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 proce-dure 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 re-tainer ring (17) or on the shoulder of the bearing cap (5). The fus-ible 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 re-tainer (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 bear-ing firmly contacts the sprbear-ing 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 rota-tion) 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. Re-tain 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 clock-wise (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.

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

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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 hydrau-lic 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 un-til 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 con-nection is vented to the atmosphere. Operate the handwheel to move the gate to approximately the half open position. This en-sures that no pressure is trapped in the body cavity.

b. If the valve is installed in a Christmas tree or other application, iso-late 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 replace-ment procedure.

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4. Loosen and remove the bonnet nuts (20).

5. Turn the stem adapter (1) clockwise until the stem threads (21) disen-gage 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

It is recommended that a new SRL gasket (23) be installed any time the bonnet has been removed. However, if necessary, the SRL gas-ket can normally be reused if it has not been scratched or other-wise damaged. An SRL gasket is most likely to be reused in

circumstances such as lack of a new gasket, lack of the special in-stallation 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 disas-sembly). Also, the O.D. sealing surface of the gasket that is exposed beyond the body (or bonnet) face should be protected from dam-age 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.

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 approxi-mately 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 be-yond 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.

2 4 3 5 SD-017330 1

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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

me-chanically 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 materi-als, etc.

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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

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 en-gagement (enen-gagement length equivalent to stud diameter). 2) Apply a light coating of valve assembly grease to the sealing

sur-faces 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, contact-ing the gasket O.D. flange. Place the load plate (2) over the bon-net 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 bot-tomed out in the body counterbore.

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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).

SD-017326 2

1

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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

me-chanically 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 spe-cial 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 de-grees 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 bon-net gasket, and the gate is pulled close to the bonbon-net.

14. Install the bonnet nuts and tighten in an even pattern. Refer to Table

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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

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) 1-13/16”10,000 psi WP 1.125 8 305 523 401 686 1-13/16”15,000 psi WP 1.250 8 421 726 553 953 2-1/16” 2000 psi WP 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 2-9/16” 5000 psi WP 1.000 8 213 361 279 474 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 D (In.) (mm) 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) Torque ¦ = .013 (N • m) 1-13/16”10,000 psi WP 1.125 28.58 8 413 706 540 925 1-13/16”15,000 psi WP 1.250 31.75 8 569 981 745 1285 2-1/16” 2000 psi WP 0.625 15.88 11 70 118 92 155 2-1/16” 3000 psi WP 0.875 22.23 9 193 328 253 429 2-1/16” 5000 psi WP 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 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