Cameron FLs Gate Valves

Operation and Maintenance ManualManually Actuated Cameron FL and FLS Gate Valves TC148 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 TC148 2 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 TC148 3 TC148 4 Table Of Contents I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Description and Features . B. Operation Instructions . . C. Dimensional Data . . . . . D. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 8 9 11 II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A. Lubrication . . . . . . . . . B. Lubrication Charts . . . . . . C. Body Cavity Lubrication . . . D. Thrust Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 TC148 5 TC148 6 . API 6A Materials Classes and Temperature Classes are available. gate. The stem shoulder can be back seated against the bonnet to isolate the stuffing box. No sealant or lubricant ports extend directly into the valve cavity. TC148 7 . All FL and FLS valves have a specially designed. 5. and NACE MR-01-75. One-piece seats and slab gate ensure reliable sealing and simplify field service. It is available in standard double flange. metal-to-metal sealing grease fitting which contains a check valve. 4. 9. BX-style metal bonnet gasket on 10. and the gate and seats can be reversed for increased life. and other special trims area available upon request. General Information A. Sealing at the gate-to-seat and the seat-to-body is metal-to-metal. 2. and seat are lubricated through the grease fitting which is located on the downstream side of the stem backseat for safety. API 6A. The gate and seat assembly seals in both directions.I. Description and Features The FL or FLS gate valve is a full-bore through-conduit valve designed and manufactured in accordance with ISO 10423. The modified Acme gate-to-stem thread allows the gate to move back and forth. 7.000 and 15. FLS valves can meet or exceed API 6FA fire safety requirements. The simplified gate and seat assembly has a minimum number of parts. to seal against the seat. threaded-end. 3. The stem.000 psi WP valves. and special block body configurations. The following are standard features of the FL and FLS gate valves: 1. Reduced-hardness bonnet bolting can be supplied for most sizes and pressures without downrating the working pressure. With minor modifications. or float. 6. 8. which allows field-replacement of the stem packing while the valve is under pressure. The seal between the valve body and bonnet is a pressure-energized. Valves for 3000 and 5000 psi WP use a flat compression-type metal gasket. The non-rising stem prevents a cavity pressure increase or displacement of cavity lubricant. and is. and then backing off (counterclockwise) ½ to ¾ turn.10. Full-Open to Full-Close 15. These temperature ratings may not be available in all working pressures. B. therefore. Special non-elastomeric stem packing designs can extend the standard temperature rating of the FL or FLS Gate Valve up to 350o F (180oC). The valve is closed by turning the handwheel clockwise (to the right) until it stops.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. Operation Instructions A gate valve should always be in either the full-open or full-closed position. ft-lb 30 35 50 65 110 260* 50 60 100 125 Maximum Opening Torque.000 psi WP Total Number of Turns. Initial torque required to open the valve is given in Table I.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. or down to -75o F (-60oC). recommended practice. 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. See the valve assembly bill-of materials for materials and descriptions of valve components. 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 . The number of turns required to move the valve from full open to full closed is given in Table I. 12. Lubricated Valve. The valve is opened by turning the handwheel counterclockwise (to the left) until it stops. See manual #SD-1792. Table I: Operating Requirements 2000 . Turning the handwheel back to the right ¼ turn will then relieve any stress in the stem. TC148 8 . Severe Service. An optional add-on torque multiplier is available for larger FL and FLS valves to provide easier operation. 11. Severe Service.000 psi WP * Optional torque multiplier recommended. Leaving the gate partially open or throttling through the valve could cause damage to the gate. Lubricated Valve. ft-lb 15 20 25 30 45 80 20 25 35 50 75 140 Maximum Opening Torque. C. Flanged (Ring Joint) 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) TC148 6-1/8” 14” 14” 14” 18-1/2” 24” 24” 170 lb 220 lb 260 lb 450 lb 750 lb 1000 lb 9 . Threaded Description 10-5/8 ” 12-3/8” 13-5/8” — — — A End-to-End.2000 psi WP Item 2-1/16” 2-9/16” 3-1/8” 4-1/8” 6-1/8” End-to-End.3000 psi WP Item 2-1/16” 2-9/16” 3-1/8” 4-1/8” 5-1/8" A End-to-End. Flanged (Ring Joint) 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 . Dimensional Data Table II: Dimensional Data . 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.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. Flanged (Ring Joint) 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 TC148 10 .Table IV: Dimensional Data .15. 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 . Flanged (Ring Joint) 14 -5/8" 16 -5/8" 18 -5/8” 21-5/8 ” 28-5/8 ” 29” A End-to-End. Flanged (Ring Joint) 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 .000 psi WP Item Description A End-to-End. Threaded Description 10-5/8 ” 12-3/8” 13-5/8 ” — — — A End-to-End.10. D. Parts List TC148 11 . For normal operation.5 18.8 9. use Cameron standard valve lubricant. use one of the two available low temperature greases.6 4.7 3.9 2.7 1.000 4-1/8” To 5000 4-1/16” 10.5 1. b. a.8 9.2 3. Lubrication Charts Table VII: Grease Volume Requirements Bore Size (in. use one of the two available high temperature greases.3 23. which is not affected by water or temperatures ranging from -20o to +250o F. Lubrication 1.000 15.9 9. Recommended body cavity lubricant. B. For normal operation. Part numbers for ordering grease as well as selection guidelines are given in Table VIII. For continuous service below 0° F. d.6 6. For continuous service below 0° F. 2. use one of the two available low temperature greases. b.5 23.6 4.6 1.7 4. Periodic Maintenance A.) (lb) Plate Travel (in. Recommended stem bearing lubricant.II. c.000 3-1/8” To 5000 3-1/16” 10.000 3-1/16” 15.000 6-1/8” To 5000 6-3/8” To 5000 TC148 12 .9 2-1/16” 2-9/16" 5-1/8” 5000 5-1/8” 10. use Cameron standard valve grease.) Pressure Rating Lubricant Volume Lubricant Weight Approximate Follower Required (cu in.7 12.3 7. For continuous service above 180o F.1 5.000 38 43 79 93 114 114 155 245 243 312 461 583 583 1.3 . which is not affected by water or temperatures ranging from -20o to +250o F.9 1.3 1.2 9.2 4. a.5 .) 1-13/16" 2-9/16" All All To 10. and well conditions. a. The service interval can vary according to application. c.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 . lubricate the body cavity before returning it to the line.Excellent (Recommended) G .Fair (Not Recommended) P . Paragraph B. b. Lubricate the body cavity after ten operating cycles. Using either a bucket-type gun. connect the grease gun coupler to the grease fitting. Body Cavity Lubrication 1. the service interval can be extended. P/N 19873-01.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 . If the valve is removed from service. or hand-held type.Poor (Not Recommended) *Available in 20 lb pail only C. P/N 19873-03. Refer to Part II. Pump the appropriate amount of lubricant into the body cavity. TC148 13 . One cycle equals opening and closing the valve one time. Remove the grease-fitting cap located on the bonnet flange OD. Normal Operating Conditions Note: Cameron lubricates gate valves on assembly. fluids used. If pressure is equalized across the valve before the valve is opened. Thrust Bearing Lubrication Note: Lubricate the thrust bearings as often as required to ensure smooth valve operation. Back off the handwheel ¼ turn. acidize through. Flush the valve with the appropriate neutralizing fluid in the line. Gate or seats are worn. d. Unusual Temporary Operating Conditions If it becomes necessary to cement through. Fluid leaks from the bonnet grease fitting. Using a hand-held grease gun. Gate and stem threads have oolost lubricant. Thrust bearings have lost oolubricant. Handwheel turns without opening or closing the valve. 2. Fluid leaks around the valve stem. Replace the stem pin. Stem packing is worn. Handwheel is not backed off. Thrust bearings are corroded. Return the valve to Cameron for repair. 2. III. TC148 Cause 14 . or subject the valve to any other unusual service. c.2. Replace the stem packing. D. 1. Replace the thrust bearings. 3. Check valve inside the grease fitting is worn. Lubricate the gate and stem through the bonnet grease fitting. Handwheel is hard to turn. Stem pin is sheared. P/N 19873-01. 2. Replace the bonnet seal ring. Pump lubricant into the fittings until clean grease appears at the bleed port on the opposite side of the bearing cap. Bonnet seal ring is worn. 1. 2. 1. Action Replace the gate or seats. Fluid leaks at the bonnet flange. Troubleshooting Symptom Fluid leaks past the gate and seat assembly. Lubricate the thrust bearings. Bonnet or body ring groove oois damaged. b. 1. Lubricate the valve body cavity. Operate the valve with fresh water or appropriate neutralizing fluid in the line. connect the grease gun fitting to the hydraulic grease fittings with a hydraulic coupler. Replace the grease fitting. proceed as follows: a. Lubricate the valve body cavity before it is put into operation. the backseat is effective. c. Turn the handwheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity and the stem moves outward. contacting the internal backseat shoulder. If pressure continues to escape. Loosen the bearing cap four complete turns. IV. Valves 10. on the outlet of a BOP or any other application in which it is the last surface barrier. Test the effectiveness of the backseat. TC148 15 . b. the backseat is ineffective. Proceed to step 3. Close the valve fully. c.Caution: When a valve is used in the lower master valve position. Repeat steps 1 and 2. Refer to Figure 3. 1) Backseat the valve again. If valve bonnet maintenance is to be performed such as stem packaging replacement. d. Bump the handwheel in the closing direction. 2.000 psi WP and Below 1. d. b. a. a. 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. precautions should be taken to ensure sub-surface safety barriers are in place and functioning. e. Bonnet Grease Fitting Replacement A. If pressure escapes quickly and then stops. Remove the grease fitting cap. 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. Backseat the valve. Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released. c. B. Do not install the fitting with the cap in place. a. high pressure fitting. Tighten the bearing cap to approximately 200 ft-lb (270 N•m). b. Torque to approximately 25 ft-lb (33 N•m). Close the valve fully. Backseat the valve.000 psi WP FL valves is a special metal-sealing.000 psi WP and Above Note: The standard grease fitting for 15. d. Remove the grease fitting from the valve bonnet. contact a Cameron representative. Bump the handwheel in the closing direction. The bonnet port housing this fitting is a special preparation without pipe threads which accepts only this type of fitting. Caution: Installing the fitting with the cap in place could damage the cap. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap. Test the effectiveness of the backseat. 2. Refer to Figure 4. 3. 5. contacting the internal backseat shoulder. b. a. Tighten the bearing cap. c. Install a new grease fitting. 1. TC148 16 . Valves 15. 4. Loosen the bearing cap four complete turns. Important: DO NOT use Teflon tape or thread sealant on these fittings. Un-backseat the valve.2) If the backseat continues to be ineffective. Turn the handwheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity and the stem moves outward. containing a check valve. V. If pressure continues to escape. the backseat is effective. If pressure escapes quickly and then stops. Un-backseat the valve. c. Removal of the Thrust Bearings 1. contact a Cameron representative. Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. the cap will rotate freely by hand. 4. A. Proceed to step 3. Torque to 80 to 100 ft-lb (100 to 135 N•m). Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap. b. Install and tighten the cap on the fitting.a. b. Remove the grease fitting cap. Remove the cap from a new grease fitting and install the fitting in the bonnet. c. Tighten the bearing cap. Caution: Installing the fitting with the cap in place prevents the fitting from seating and could cause damage to the cap. Stem Pin and Thrust Bearing Replacement Note: The stem thrust bearings can be replaced while the valve is under pressure in the line. Loosen the bearing cap. d. 6. Repeat steps 1 and 2. 3. Do not install the fitting with the cap in place. TC148 17 . the backseat is ineffective. Remove the grease fitting from the valve bonnet. using a 24” pipe wrench. Torque to approximately 25 ft-lb (33 N•m). 2) If the backseat continues to be ineffective. 5. This procedure unseats the metal seal and vents any pressure on the fitting. After two or three turns. Tighten the bearing cap to approximately 200 ft-lb (270 N•m). a. 1) Backseat the valve again. Using a punch.Caution: If the cap does not rotate freely after three turns. Pack the bearings with clean grease. Discard any pitted. 5. drive the stem pin from the stem adapter. drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. Caution: Do not strike the bearings. Remove the new bearings from the protective packaging. or damaged bearings or races. Carefully clean the stem adapter. is not retained inside. 8. TC148 18 . Tighten the cap and contact a Cameron representative. Replace the stem adapter if either of the bearing surfaces on the adapter shoulder is damaged. 1. ensuring that the adapter is not damaged. Inspect the bearing cap to ensure that an extra race. 2. 2. If the bearing cap rotates freely. Place each bearing between a pair of carefully cleaned races. 3. This can be checked by tapping on the stem adaptor so it moves relative to the bearing cap. 6. Replace the stem adapter O-ring if necessary. 6. or stem adapter with the punch or hammer. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. B. 9. 3. Using a punch. 4. 4. cracked. held by grease tension. Installation of the New Thrust Bearings. 5. Remove both sets of bearings and bearing races from the stem adapter. races. DO NOT remove the cap. 7. the packing gland may be moving outward with the bearing cap. If the stem adaptor does not move inward or continues to back out with the bearing cap. Insert the stem adapter over the end of the stem and align the pin hole in the adapter with the hole in the stem. remove the cap from the bonnet. Remove the adapter from the stem. the backseat is effective. Close the valve fully. Loosen the bearing cap four complete turns. Repeat steps 1 and 2. 4) If pressure escapes quickly and then stops. Inject grease through the bearing cap grease fittings until the excess grease passes through the bleed port. 11. b. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. a. 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. Turn the handwheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity and the stem moves outward.10. 1) Remove the bonnet grease fitting cap. Refer to Figure 3. 5) If pressure continues to escape. 12. c. Valves 10. Backseat the valve. 13. contacting the internal backseat shoulder. TC148 19 . Stem Packing Replacement with Pressure in the Valve A. and tighten to approximately 200 ft-lb (270 N•m). Removal of the Stem Packing 1. VI. the backseat in ineffective. d. a) Backseat the valve again. Backseat the valve. Proceed to step 3.000 psi WP and Below. a. 3) Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped b the backseating process is released. Install the cap. Clean the bearing cap and lubricate the threads. This procedure will confirm that the stem backseating shoulder is not contacting the bonnet shoulder. 2. Bump the handwheel in the closing direction. 9. 6. 3. 10. 1) Thread the packing sleeve into the bonnet packing gland preparation until the sleeve bottoms out. pump the packing out into the recessed area of the packing sleeve. a. 2) Using a grease gun attached to the bonnet grease fitting. Use packing sleeve P/N 21168 for 1” stem size and packing sleeve P/N 233842 for 1 ¼” stem size. contact a Cameron representative. Remove the packing gland. Refer to Figure 4. This procedure unseats the metal seal and vents any pressure on the fitting. Remove the adapter from the stem. b) If the backseat continues to be ineffective. Proceed to step 3. 4) If pressure continues to escape. ensuring that the adapter is not damaged. 8. Ensure that the threads on the bonnet neck OD are not damaged.000 psi WP and Above. TC148 20 . the backseat is effective. Remove the cap from the bonnet. 3) If pressure escapes quickly and then stops. 11. Repeat steps 1 and 2. Loosen the packing gland.b) If the backseat continues to be ineffective. a) Backseat the valve again. the backseat in ineffective. 4. Remove the handwheel and bearing cap. 5. Remove the stem packing and backup ring (if applicable). Using a punch. 1) Remove the grease fitting cap. contact a Cameron representative. b. Remove both sets of bearings and bearing races from the stem adapter. Valves 15. 7. 2) Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. drive the stem pin from the stem adapter. Clean the grease from the stuffing box bore so that hydraulic lock will not prevent the installation of new packing. Lightly grease the new stem packing. The nose and threads of the packing gland.3) Remove the sleeve from the bonnet. B. The stuffing box bore. (Special tools required. remove the stem packing by one of the following methods: 1) Pump the packing out with grease until the grease bypasses or the packing refuses to extrude further. c. 4. If a packing back-up ring is required. TC148 21 . HT-20 packing: Call Cameron service. d. If a packing sleeve is not available. Inspect the stuffing box to ensure that the bore is clean and free of pits or scars. 7. b. Varipak or SLS packing: Install with open-end facing pressure. 5. push the packing into the stuffing box. c. J packing or U packing: Install with rounded nose facing pressure. b. not user replaceable). Remove the packing gland and lubricate the stem OD. Caution: Do not damage the stem or packing bore. Inspect the stem to ensure that the surface is free of burrs and pits. 6. Install it over the stem and into the bonnet as follows: a. Using the packing gland as a pushing tool. 3. The stem. 2) Pull the packing out with a corkscrew. The ID and OD of the stem packing. install it over the stem. 2. b. Apply a light coat of grease to: a. Installation of the New Packing 1. 21. Clean the bearing cap and lubricate the threads. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter. and torque to 200 ft-lb (270 N•m). Carefully clean the stem adapter. Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly. 19. Inspect the bearing cap to ensure that an extra race. 15. held by grease tension is not retained inside. 22. Insert the stem adapter over the end of the stem and align the pinhole in the adapter with the hole in the stem. TC148 22 . or cracks. races. Using a punch. scores. or stem adapter with the punch or hammer. Install the packing gland and apply approximately 200 ft-lb (270 N•m) of torque. drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder. Refer to Part II. 9. Install the cap. 13. 11.8. 10. Inject grease through the bearing cap grease fitting until the excess grease passes through the bleed port. 17. Caution: Do not strike the bearings. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. Place each bearing between a pair of carefully cleaned races. Replace if damaged. Lubricate the body cavity. 16. Pack the bearings with grease. Replace the stem adapter O-ring if necessary. 14. 20. ensuring that the bonnet threads are not damaged. 12. This procedure will confirm that the stem backseating shoulder is not contacting the bonnet shoulder. 18. Inspect the bearings and bearing races on the stem adapter for pits. Replace any damaged parts. Flush the body cavity thoroughly with suitable solvent and wipe clean with a rag. 4. Note: If the seats are stuck. Support the bonnet and turn the handwheel clockwise until the stem completely backs out of the gate.VII. stroke the valve one complete cycle. 5. 2. Remove the bonnet assembly. Gate and Seat Inspection 1. 6. Release the cavity pressure by bleeding the cavity pressure through the bonnet grease fitting. insert a screwdriver in the groove on the OD of the seat and pry the seat out. 8. Pull the gate from the body. twisted. Gate and Seat Disassembly 1. a. 3. Gate and Seat Replacement A. Remove all bonnet nuts. Inspect the cavity parts for damage. Remove the seats. Ensure that the seal rings are not damaged. Ensure that the gate is not cut or damaged. TC148 23 . With the bonnet grease fitting still vented. c. Ensure that the seats are not cut or damaged. B. Isolate the valve from the line pressure. ending in the full open position. Ensure that the retainer plate is not bent. 9. or distorted. b. d. Important: Solid material should not be built up on the retainer plate surfaces. 7. Caution: Any trapped pressure will be vented through the bonnet grease fitting or end flange. 2. 4. Remove the seal ring from the bonnet groove. 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. Ensure that the body cavity is free of all foreign matter such as solid particles. Install the gate into the cavity between the seats. Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal face. C. 7. The flat center part of the retainer plate goes against the cavity bottom. Apply a very thin film of clean grease to the bonnet seal ring and groove. Clean the grooves and/or seating area of the body and bonnet. seats. Install the new seal ring in the bonnet groove. Install the seal rings into the face groove(s) located in the seats. Push the gate all the way to the bottom of the cavity and pack the remaining space with grease. 9. 6. Clean the body cavity with a suitable cleaning solvent. and seat seal rings. a. 5. Thread the stem into the gate by turning the handwheel counterclockwise. On valves 10. and the semi-circular cut-outs must be aligned with the seat pockets. Gate and Seat Assembly 1. 8. 5. trash. Apply a thin coat of clean grease to the body cavity. Note: The FL valve uses one seal ring per seat. grit. 3. On valves 5000 psi WP and below. Install the U-shaped retainer plate in the bottom of the body cavity. retainer plate. 2. 6. TC148 24 . b. the FLS uses two per seat. gate.3. Install the seats into the seat pockets. rotate the bonnet until the grease fitting is 90° from the gate bore. 4.000 psi WP and above. Install the bonnet over the body studs. 10. rotate the bonnet so that the bonnet locating pins in the body align with the pinholes in the bonnet. etc. 750-10 .TPI . L7M (80 ksi) B7.125-8 1. Hand tighten the bonnet nuts. N•m Per API 6A: Preload = . 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. Evenly tighten the bonnet nuts. 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 . Pull the bonnet down over the studs. L7. 14.750-10 .50Sy English Units B7M.125-8 1.625-8 TC148 Recommended Makeup Torques.375-8 1. (See Table Below.875-9 1.TPI .375-8 1.11.250-8 1. Bolt Size Nom OD . Ft-Lbf Per API 6A: Preload = .625-11 .) Note: The raised bonnet face on valves 10. L7.625-8 Bolt Size Nom OD . L7M (80 ksi) B7.875-9 1. 12. 13.50Sy Metric Units B7M.500-8 1.625-11 .000 psi and above will fully contact the body face when the bonnet nuts are tight.500-8 1.000-8 1. Ensure that the gate is not on the bottom of the cavity.250-8 1.000-8 1. TC148 26 . stem. 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. 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.D. 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). seat. etc. Part I. trim) be included as a check on the assembly number.). Cameron personnel can then check the latest revision of the assembly bill-of-material to obtain the appropriate and current replacement part number.VIII. pressure. but this is not necessary if the assembly number is clearly readable. TC148 27 . the only way to ensure getting the updated component is to reference the valve assembly number and to reference the part by description (gate. The valve assembly part number is stamped on the valve body nameplate. If an engineering change has been implemented to the valve assembly to replace one component part number with another. operating in the temperature ranges between -20 and 250oF (-29 and 121o C). Part descrip- tions are shown in the parts list. It is recommended that a description of the valve assembly (size. Contact your Cameron representative for replacement parts for FLS and all other FL gate valves. 000 PSI WP TC148 28 .Figure 1 FL MANUAL GATE VALVE ALL EXCEPT 3-1/16 15. 000 PSI WP TC148 29 .FIGURE 2 FL MANUAL GATE VALVE 3-1/16 15. FIGURE 3 FL GATE VALVE PREPPED FOR ACTUATOR ALL SIZES AND PRESSURES TC148 30 . TC148 31 . TC148 32 . TC148 33 . TC148 34 . TC148 35 . TC148 36 . TC148 37 . TC148 38 . TC148 39 . TC148 40 . TC148 41 . TC148 42 . TC148 43 . TC148 44 . TC148 45 . TC148 46 . TC148 47 . TC148 48 . TC148 49 . TC148 50 . TC148 51 . TC148 52 . TC148 53 . TC148 54 .