Operation and Maintenance Manual

Manually Actuated FL and FLS Gate Valves

TC148

All the information contained in this manual is the exclusive property of Cameron. Any reproduction or use of the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden without the written permission of Cameron or its authorized agent.

Initial Release A1 April 1992 Revision B1 April 1994 Revision C1 June, 1997

Copyright 1997 all rights reserved by Cooper Cameron Corporation Cameron Division

TC148 Rev C1 6/97

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 injury or death to any person resulting in whole or in part from repairs performed by other than authorized Cameron personnel. Such unauthorized repairs shall also serve to terminate any contractual or other warranty, if any, on the equipment and may also result in the 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. P.O. Box 1212 Houston, Texas 77251-1212 ph: 713-939-2211 http://www.coopercameron.com

TC148 Rev C1 6/97

CONTENTS
I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 A. Description and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 B. Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 C. Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 D. Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 II. Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 A. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 C. Body Cavity Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 D. Thrust Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 III. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 IV. Bonnet Grease Fitting Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 A. Valves 10,000 psi WP and Below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 B. Valves 15,000 psi WP and Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 V. Stem Shear Pin and Thrust Bearing Replacement. . . . . . . . . . . . . . . . . . . . . . 17 A. Removal of the Thrust Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 B. Installation of the New Thrust Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . 17 VI. Stem Packing Replacement with Pressure in the Valve. . . . . . . . . . . . . . . . . . 18 A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 B. Installation of the New Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 C. Gate and Seat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 VIII. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

TC148 Rev C1 6/97

I. GENERAL INFORMATION A. Description and Features The FL or FLS gate valve is a full-bore through-conduit valve designed and manufactured in accordance with API 6A and NACE MR-01-75. It is available in standard double flange, threaded-end, and special block body configurations. The following are standard features of the FL and FLS gate valves: 1. Sealing at the gate-to-seat and the seat-to-body is metal-to-metal. 2. The simplified gate and seat assembly has a minimum number of parts. One-piece seats and slab gate ensure reliable sealing and simplify field service. The modified Acme gate-to-stem thread allows the gate to move back and forth, or float, to seal against the seat. 3. The gate and seat assembly seals in both directions, and the gate and seats can be reversed for increased life. 4. The stem shoulder can be backseated against the bonnet to isolate the stuffing box, which allows field-replacement of the stem packing while the valve is under pressure. 5. The non-rising stem prevents a cavity pressure increase or displacement of cavity lubricant. 6. All FL and FLS valves have a specially designed, metal-to-metal sealing grease fitting which contains a check valve. The stem, gate, and seat are lubricated through the grease fitting which is located on the downstream side of the stem backseat for safety. No sealant or lubrication ports extend directly into the valve cavity. 7. The seal between the valve body and bonnet is a pressure-energized, BX-style metal bonnet gasket on 10,000 and 15,000 psi WP valves. Valves for 3000 and 5000 psi WP use a flat compression-type metal gasket. 8. API 6A Materials Classes and Temperature Classes are available, and other special trims are available upon request. Reduced-hardness bonnet bolting can be supplied for most sizes and pressures without downrating the working pressure. 9. With minor modifications, FL and FLS valves can meet or exceed API 6FA fire safety requirements. 10. Special non-elastomeric stem packing designs can extend the standard temperature rating of the FL or FLS Gate Valve up to 350 F, or down to -75 F. These temperature ratings may not be available in all working pressures.
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11. An optional add-on torque multiplier is available for larger FL and FLS valves to provide easier operation. 12. See the valve assembly bill-of materials for materials and descriptions of valve components. B. Operation Instructions A gate valve should always be in either the full-open or full-closed position. Leaving the gate partially open or throttling through the valve could cause damage to the gate. The valve is opened by turning the handwheel counterclockwise (to the left) until it stops. Turning the handwheel back to the right 1/4 turn will then relieve any stress in the stem,and is, therefore, recommended practice. Initial torque required to open the valve is given in Table I. The valve is closed by turning the handwheel clockwise (to the right) until it stops, and then backing off (counterclockwise) 1/2 to 3/4 turn. The number of turns required to move the valve from full open to full closed is given in Table I. Table I: Operating Requirements
2000 - 3000 psi WP 5000 psi WP Valve Bore Size 21/16" 29/16" 31/8" 41/16" 51/8" 63/8" 21/16" 29/16" 31/8" 41/16" 51/8" 63/8" Expected Opening Torque, Lubricated Valve, 15 20 25 30 45 80 20 25 35 50 75 140 ft-lb Maximum Opening 30 40 60 80 130 235 45 65 95 135 220 395 Torque, Severe Service, ft-lb Total Number of Turns, 121/3 151/8 181/8 231/4 271/2 333/4 121/3 151/8 181/8 231/4 271/2 333/4 Full-open to Full-closed

10,000 psi WP Valve Bore Size Expected Opening Torque, Lubricated Valve, ft-lb Maximum Opening Torque, Severe Service, ft-lb Total Number of Turns, Full-open to Full-closed 1 /16" 30
13

15,000 psi WP 2 /16" 50

9

2 /16" 35

3 /16" 65

4 /16" 110

5 /8" 260*

1 /16" 50

13

21/16" 60

29/16" 100

31/16" 125

80 121/3

85 121/3

130 151/8

170 181/8

320 231/4

690* 29

125 121/3

155 121/3

265 153/4

335 227/8

*Optional torque multiplier recommended. See manual #SD-1792.

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C. Dimensional Data

3-3/4"

Figure 1

SD-10489-99

Table II: Dimensional Data - 2000 psi WP

Item A B C D E F Description
End-to-End, Flanged (Ring Joint) Extreme Width of Body Center of Port to Top of Stem Adapter Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim Handwheel OD Weight (Flanged)

21/16" 115/8" 61/8" 13" 51/4" 153/8" 14" 160 lb

29/16" 131/8" 71/8" 3313/16" 6" 161/8" 14" 200 lb

31/8" 141/8" 73/4" 1613/16" 71/8" 191/16" 14" 240 lb

41/8" 171/8" 93/4" 187/16" 91/8" 2011/16" 14" 350 lb

61/8" 221/8" 123/8" 223/4" 127/8" 24" 181/2" 800 lb

Table III: Dimensional Data - 3000 psi WP

Item A A B C D E F Description
End-to-End, Threaded End-to-End, Flanged (Ring Joint) Extreme Width of Body Center of Port to Top of Stem Adapter Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim Handwheel OD Weight (Flanged)

21/16" 105/8" 145/8" 63/4" 13" 55/8" 153/8" 14" 170 lb

29/16" 123/8" 165/8" 75/8" 3313/16" 61/2" 161/8" 14" 220 lb

31/8" 135/8" 171/8" 71/2" 1613/16" 73/8" 191/16" 14" 260 lb

41/8" 201/8" 101/2" 187/16" 91/8" 2011/16" 181/2" 450 lb

51/8" 241/8" 21" 215/16" 113/8" 229/16" 24" 750 lb

61/8" 241/8" 123/4" 223/4" 127/8" 24" 24" 1000 lb

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Table IV: Dimensional Data - 5000 psi WP

Item A A A B C D E F Description
End-to-End, Threaded End-to-End, Flanged (Ring Joint) End-to-End, Butt Weld Extreme Width of Body Center of Port to Top of Stem Adapter Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim Handwheel OD Weight (Flanged)

21/16" 105/8" 145/8" 7" 151/8" 55/8" 173/8" 14" 175 lb

29/16" 123/8" 165/8" 83/16" 1515/16" 61/2" 181/8" 14" 230 lb

31/8" 135/8" 185/8" 91/4" 1613/16" 73/8" 191/16" 181/2" 360 lb

41/8" 215/8" 211/2" 1013/16" 187/16" 91/8" 2011/16" 181/2" 520 lb

51/8" 285/8" 213/4" 215/16" 113/8" 239/16" 24" 800 lb

61/8" 29" 141/8" 223/4" 127/8" 24" 24" 1160 lb

Table V: Dimensional Data - 10,000 psi WP

Item A B C D E F Description
End-to-End, Flanged (Ring Joint) Extreme Width of Body Center of Port to Top of Stem Adapter Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim Handwheel OD Weight

113/16" 181/4" 91/16" 151/8" 53/4" 173/8" 14" 250 lb

21/16" 201/2" 93/8" 151/8" 57/8" 173/8" 181/2" 275 lb

29/16" 221/4" 913/16" 1513/16" 613/16" 181/8" 181/2" 370 lb

31/16" 243/8" 101/4" 167/8" 81/16" 181/16" 24" 480 lb

41/16" 263/8" 1213/16" 1911/16" 101/16" 2015/16" 24" 880 lb

51/8" 29" 231/2" 237/8" 131/8" 251/4" 24" 1750 lb

Table VI: Dimensional Data - 15,000 psi WP

Item A B C D E F Description
End-to-End, Flanged (Ring Joint) Extreme Width of Body Center of Port to Top of Stem Adapter Center of Port to Bottom of Body Center of Port to Top of Handwheel Rim Handwheel OD Weight

113/16" 18" 97/8" 151/8" 57/8" 173/8" 181/2" 275 lb

21/16" 19" 97/8" 151/8" 61/8" 173/8" 181/2" 300 lb

29/16" 21" 111/2" 173/16" 75/16" 199/16" 181/2" 560 lb

31/16" 239/16" 139/16" 2015/16" 91/4" 223/16" 24" 890 lb

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D. Parts List

Item
1 4 2 6 5 5 8 9 6 5 10 12 11 13 5 3 7

Description

14

15 16 18

1 2 3 4 5 6 7 8 9 10 11 12* 13 14 15 16 17 18 19 20 21 22 23 24* 25 26

Handwheel Grease Fitting Bearing Cap O-Ring Race Bearing O-Ring Stem Adapter Stem Shear Pin Packing Gland Stem Packing Packing Backup Ring Bonnet Nut Bonnet Stud Bonnet Grease Injection Fitting Bonnet Seal Ring Stem Gate Seat Seal Ring, OD Seal Ring, ID (FLS Only) Retainer Plate Dowel Pin Body Nameplate *Not Supplied in all sizes and pressures.

19

21 20 23 17 24

22

26 25

Figure 2

Typical FL or FLS Valve

SD-10387-99
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11

II. PERIODIC MAINTENANCE A. Lubrication 1. Recommended body cavity lubricant. a. For normal operation, use Cameron valve lubricant CI-14 or TF-41, greases not affected by water or temperatures ranging from -20 to +250 F. b. For continuous service below 0 F, use a low temperature grease such as arctic grease NS-14. 2. Recommended stem bearing lubricant a. For normal operation, use Cameron valve lubricant CI-14 or TF-41, greases not affected by water or temperatures ranging from -20 to +250 F. b. For continuous service below 0 F, use a low temperature grease such as arctic grease NS-14. B. Lubrication Charts Table VII: Grease Volume Requirements
Bore Size (in.) 113/16 21/16 29/16 29/16 31/8 31/16 31/16 41/8 41/16 51/8 51/8 61/8 63/8 Pressure Rating All All To 10,000 15,000 To 5000 10,000 15,000 To 5000 10,000 5000 10,000 To 5000 To 5000 Lubricant Volume Required (cu in.) 38 43 79 93 114 114 155 245 243 312 461 583 583 Lubricant Weight (lb) 1.5 1.7 3.2 3.7 4.6 4.6 6.2 9.8 9.7 12.5 18.5 23.3 23.3 Approximate Follower Plate Travel (in.) .5 .7 1.3 1.6 1.9 1.9 2.6 4.2 4.1 5.3 7.8 9.9 9.9
SD-4130

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Table VIII: Lubricant Selection

Service Lubricant Name Operational Properties
With H2S (Sour Crude or Gas)

Solvent

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

Low Temp. to -75 F

Standard Crude

With Gas Well Condensates

High Temp. RT to +650 F

Very High CO2

120 lb Drum

Standard Arctic Diesel Resistant High Temperature High Temperature E - Execllent G - Good

CI-14 or TF-41 NS-14 SS-14 or TS-41 HT-14S Moly 101 F - Fair P - Poor

E E E G G

P E P F P

P P E P P

P P P E E

F F G F G

F F G F F

P P G P P

Mineral Spirits Mineral Spirits Alcohol Mineral Spirits Mineral Spirits

700149 700123 700150 700217 710194

700667 700671 700675 700679 700679

700668 700672 700676 700680 700680

700669 700673 700677 700681 700681

700670 700674 700678 700682 700682

Example for Ordering: Order Part Number 700672 for 25 lb of NS-14 SD-4185

C. Body Cavity Lubrication 1. Normal Operating Conditions

Note: Cameron lubricates gate valves on assembly. Lubricate the body cavity after ten operating cycles. One cycle equals opening and closing the valve one time. The service interval can vary according to application, fluids used, and well conditions. If pressure is equalized across the valve before the valve is opened, the service interval can be extended. If the valve is removed from service, lubricate the body cavity before returning it to the line.
a. Remove the grease fitting cap located on the bonnet flange OD. b. Using either a bucket-type gun, P/N 19873-03, or hand-held type, P/N 19873-01, connect the grease gun coupler to the grease fitting. c. Pump the appropriate amount of lubricant into the body cavity. Refer to Part I, Paragraph B. 2. Unusual Temporary Operating Conditions If it becomes necessary to cement through, acidize through, or subject the valve to any other unusual service, proceed as follows: a. Lubricate the valve body cavity before it is put into operation.

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400 lb Drum

(Per Pound)

25 lb Pail

5 lb Can

Diesel

b. Flush the valve with the appropriate neutralizing fluid in the line. c. Operate the valve with fresh water or appropriate neutralizing fluid in the line. d. Lubricate the valve body cavity. D. Thrust Bearing Lubrication

Note: Lubricate the thrust bearings as often as required to ensure smooth valve operation.
1. Using a hand-held grease gun, P/N 19873-01, connect the grease gun fitting to the hydraulic grease fittings with a hydraulic coupler. 2. Pump lubricant into the fittings until clean grease appears at the bleed port on the opposite side of the bearing cap. III. TROUBLESHOOTING
Symptom Fluid leaks past the gate and seat assembly. Cause 1. Gate or seats are worn. 2. Handwheel is not backed off. 1. Bonnet seal ring is worn. 2. Bonnet or body ring groove is damaged. Check valve inside the grease fitting is worn. 1. Thrust bearings have lost lubricant. 2. Thrust bearings are corroded. 3. Gate and stem threads have lost lubricant. Stem shear pin is sheared. Action Replace the gate or seats. Back off the handwheel 1/4 turn. Replace the stem packing. Replace the bonnet seal ring. Return the valve to Cameron for repair. Replace the grease fitting. Lubricate the thrust bearings. Replace the thrust bearings. Lubricate the gate and stem through the bonnet grease fitting. Replace the stem shear pin.

Fluid leaks around the valve stem. Stem packing is worn. Fluid leaks at the bonnet flange. Fluid leaks from the bonnet grease fitting.

Handwheel is hard to turn.

Handwheel turns without opening or closing the valve.

Caution: When a valve is used in the lower master valve position, on the outlet of a BOP or any other application in which it is the last surface barrier, precautions should be taken to ensure sub-surface safety barriers are in place and functioning. If valve bonnet maintenance is to be performed such as stem packaging replacement, bearing replacement or shear pin replacement consideration should be given with respect to number of barriers required by the customer and the local statutory requirements.
IV. BONNET GREASE FITTING REPLACEMENT A. Valves 10,000 psi WP and Below 1. Backseat the valve

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a. Close the valve fully. b. Loosen the bearing cap four complete turns. c. Turn the handwheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity and the stem moves outward, contacting the internal backseat shoulder. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 3. a. Remove the grease fitting cap.
1/8" Diameter Pin Bonnet Grease Fitting Cap

b. Trip the ball in the grease fitting check valve by inserting a 1/8" diameter by 3/4" long pin into the run of the fitting. c. Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released.

Pressure In Bonnet

Pressure Bleed By

Grease Fitting Body

Hex

SD-10268-99

Figure 3 Low Pressure Grease Fitting

d. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. e. If Pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. 2) If the backseat continues to be ineffective, contact a Cameron representative. 3. Remove the grease fitting from the valve bonnet. 4. Install a new grease fitting.

Caution: Installing the fitting with the cap in place could damage the cap. Do not install the fitting with the cap in place.
5. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb. b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap.
15

TC148 Rev C1 6/97

c. Tighten the bearing cap to approximately 200 ft-lb. B. Valves 15,000 psi WP and Above

Note: The standard grease fitting for 15,000 psi WP FL valves is a special metal-sealing, high pressure fitting, containing a check valve. The bonnet port housing this fitting is a special preparation without pipe threads which accepts only this type of fitting. Important: DO NOT use Teflon tape or thread sealant on these fittings.
1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns.

Grease Fitting Body

Bonnet

Grease Fitting Cap

Pressure In Bonnet Pressure Bleed By Grease Fitting Gland Hex

SD-10267-99

Figure 4 High Pressure Grease Fitting

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. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. Refer to Figure 4. a. Remove the grease fitting cap. b. Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. c. If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. d. If pressure continues to escape, the backseat is ineffective. 1) Backseat the valve again. Repeat steps 1 and 2. 2) If the backseat continues to be ineffective, contact a Cameron representative. 3. Remove the grease fitting from the valve bonnet.

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4. Remove the cap from a new grease fitting and install the fitting in the bonnet. Torque to 80 to 100 ft-lb. 5. Install and tighten the cap on the fitting.

Caution: Installing the fitting with the cap in place prevents the fitting from seating and could cause damage to the cap. Do not install the fitting with the cap in place.
6. Un-backseat the valve. a. Tighten the bearing cap. Torque to approximately 25 ft-lb. b. Turn the handwheel counterclockwise (opening direction) one full turn while simultaneously tightening the bearing cap. c. Tighten the bearing cap to approximately 200 ft-lb. V. STEM SHEAR PIN AND THRUST BEARING REPLACEMENT

Note: The stem thrust bearings can be replaced while the valve is under pressure in the line.
A. Removal of the Thrust Bearings 1. Loosen the bearing cap, using a 24" pipe wrench. After two or three turns, the cap will rotate freely by hand.

Caution: If the cap does not rotate freely after three turns, the packing gland may be moving outward with the bearing cap. This can be checked by tapping on the stem adaptor so it moves relative to the bearing cap. If the stem adaptor does not move inward or continues to back out with the bearing cap, DO NOT remove the cap. Tighten the cap and contact a Cameron representative.
2. If the bearing cap rotates freely, remove the cap from the bonnet. 3. Using a punch, drive the stem shear pin from the stem adapter, ensuring that the adapter is not damaged. 4. Remove the adapter from the stem. 5. Remove both sets of bearings and bearing races from the stem adapter. 6. Discard any pitted, cracked, or damaged bearings or races. 7. Replace the stem adapter if either of the bearing surfaces on the adapter shoulder is damaged. B. Installation of the New Thrust Bearings 1. Remove the new bearings from the protective packaging.

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2. Pack the bearings with clean grease. 3. Place each bearing between a pair of carefully cleaned races. 4. Carefully clean the stem adapter. 5. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter.

Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly.
6. Insert the stem adapter over the end of the stem and align the pin hole in the adapter with the hole in the stem. 7. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder.

Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer.
8. Replace the stem adapter O-ring if necessary. 9. Inspect the bearing cap to ensure that an extra race, held by grease tension, is not retained inside. 10. Clean the bearing cap and lubricate the threads. 11. Install the cap, and tighten to approximately 200 ft-lb. 12. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not contacting the bonnet shoulder. 13. Inject grease through the bearing cap grease fittings until the excess grease passes through the bleed port. VI. STEM PACKING REPLACEMENT WITH PRESSURE IN THE VALVE A. Removal of the Stem Packing

Note: If there is no pressure in the valve, proceed to step 3.

1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete turns.

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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. d. Bump the handwheel in the closing direction. 2. Test the effectiveness of the backseat. a. Valves 10,000 psi WP and Below. Refer to Figure 3. 1) Remove the bonnet grease fitting cap. 2) Trip the ball in the grease fitting check valve by inserting an 1/8 diameter by 3/4 long pin into the run of the fitting. 3) Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released. 4) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 5) If pressure continues to escape, the backseat is ineffective. a) Backseat the valve again. Repeat steps 1 and 2. b) If the backseat continues to be ineffective, contact a Cameron representative. b. Valves 15,000 psi WP and Above. Refer to Figure 4. 1) Remove the grease fitting cap. 2) Place a wrench on the hex preparation of the fitting gland and back out the fitting approximately one turn. This procedure unseats the metal seal and vents any pressure on the fitting. 3) If pressure escapes quickly and then stops, the backseat is effective. Proceed to step 3. 4) If pressure continues to escape, the backseat is ineffective. a) Backseat the valve again. Repeat steps 1 and 2. b) If the backseat continues to be ineffective, contact a Cameron representative. 3. Remove the handwheel and bearing cap. 4. Remove the cap from the bonnet.

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5. Using a punch, drive the stem shear pin from the stem adapter, ensuring that the adapter is not damaged. 6. Remove the adapter from the stem. 7. Remove both sets of bearings and bearing races from the stem adapter. 8. Loosen the packing gland. 9. Ensure that the threads on the bonnet neck OD are not damaged. 10. Remove the packing gland. 11. Remove the stem packing and backup ring (if applicable). a.Use packing sleeve P/N 21168 for 1" stem size and packing sleeve P/N 233842 for 11/4" stem size. 1) Thread the packing sleeve into the bonnet packing gland preparation until the sleeve bottoms out. 2) Using a grease gun attached to the bonnet grease fitting, pump the packing out into the recessed area of the packing sleeve. 3) Remove the sleeve from the bonnet. b. If a packing sleeve is not available, remove the stem packing by one of the following methods: 1) Pump the packing out with grease until the grease bypasses or the packing refuses to extrude further. 2) Pull the packing out with a corkscrew.

Caution: Do not damage the stem or packing bore.

B. Installation of the New Packing 1. Clean the grease from the stuffing box bore so that a hydraulic lock will not prevent the installation of new packing. 2. Inspect the stuffing box to ensure that the bore is clean and free of pits or scars. 3. Inspect the stem to ensure that the surface is free of burrs and pits. 4. Apply a light coat of grease to: a. The stem b. The stuffing box bore
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c. The ID and OD of the stem packing d. The nose and threads of the packing gland. 5. Lightly grease the new stem packing. Install it over the stem and into the bonnet as follows: a. J packing or U packing: Install with rounded nose facing pressure. b. Varipak packing: Install with open end facing pressure. c. HT-20 packing: Call Cameron service. (Special tools required; not user replaceable). 6. Using the packing gland as a pushing tool, push the packing into the stuffing box. 7. Remove the packing gland and lubricate the stem OD. If a packing back-up ring is required, install it over the stem. 8. Install the packing gland and apply approximately 200 ft-lb of torque, ensuring that the bonnet threads are not damaged. 9. Inspect the bearings and bearing races on the stem adapter for pits, scores, or cracks. Replace if damaged. 10. Pack the bearings with grease. 11. Place each bearing between a pair of carefully cleaned races. 12. Carefully clean the stem adapter. 13. Install one set of bearings and races over the bottom of the adapter and one set over the top of the adapter.

Note: The adapter O-ring may be removed temporarily to allow for the installation of the top bearing and race assembly.
14. Insert the stem adapter over the end of the stem and align the pin hole in the adapter with the hole in the stem. 15. Using a punch, drive in the stem pin and ensure that the pin does not protrude over the OD of the adapter shoulder.

Caution: Do not strike the bearings, races, or stem adapter with the punch or hammer.
16. Replace the stem adapter O-ring if necessary. 17. Inspect the bearing cap to ensure that an extra race, held by grease tension, is not retained inside.

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18. Clean the bearing cap and lubricate the threads. 19. Install the cap, and torque to 200 ft-lb. 20. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This procedure will confirm that the stem backseating shoulder is not contacting the bonnet shoulder. 21. Inject grease through the bearing cap grease fitting until the excess grease passes through the bleed port. 22. Lubricate the body cavity. Refer to Part I. VII. GATE AND SEAT REPLACEMENT A. Gate and Seat Disassembly 1. Isolate the valve from the line pressure. 2. Release the cavity pressure by bleeding the bonnet grease fitting. 3. Fully open the valve to ensure that the stem is completely within the gate neck. 4. Remove the bonnet nuts. 5. Support the bonnet and turn the handwheel clockwise until the stem completely backs out of the gate. 6. Remove the bonnet assembly. 7. Pull the gate from the body. 8. Remove the seats.

Note: If the seats are stuck, insert a screwdriver in the groove on the OD of the seats and pry out the seats.
9. Remove the retainer plate from the bottom of the body cavity. 10. Flush the body cavity thoroughly with a suitable solvent and wipe clean with a rag. B. Gate and Seat Inspection 1. Inspect the cavity parts for damage. a. Ensure that the retainer plate is not bent, twisted, or distorted.

Important: Solid material should not be built up on the retainer plate surfaces.

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b. Ensure that the seal rings are not damaged. c. Ensure that the seats are not cut or damaged. d. Ensure that the gate is not cut or damaged. 2. Replace any damaged parts. 3. Ensure that the body cavity is free of all foreign matter such as solid particles, grit, trash, etc. 4. Clean the body cavity with a suitable cleaning solvent. 5. Apply a thin coat of clean grease to the body cavity, gate, retainer plate, seats, and seat seal rings. 6. Install the U-shaped retainer plate in the bottom of the body cavity. The flat center part of the retainer plate goes against the cavity bottom, and the semi-circular cut-outs must be aligned with the seat pockets. C. Gate and Seat Assembly 1. Install the seal rings into the face groove(s) located in the seats.

Note: The FL valve uses one seal ring per seat; the FLS uses two per seat.
2. Install the seats into the seat pockets.

Note: The grooved seat face with its seal ring(s) goes against the body seat pocket seal face. Do not apply more than a very thin film of grease to the back face of the seat and seal ring(s) or the seal face on the body seat pocket.
3. Install the gate into the cavity between the seats. 4. Push the gate all the way to the bottom of the cavity and pack the remaining space with grease. 5. Remove the seal ring from the bonnet groove. 6. Clean the grooves and/or seating area of the body and bonnet. 7. Apply a very thin film of clean grease to the bonnet seal ring and groove. 8. Install the new seal ring in the bonnet groove. 9. Install the bonnet over the body studs. a. On valves 5000 psi WP and below, rotate the bonnet so that the bonnet locating pins in the body align with the pin holes in the bonnet.

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b. On valves 10,000 psi WP and above, rotate the bonnet until the grease fitting is 90 from the gate bore. 10. Thread the stem into the gate by turning the handwheel counterclockwise. 11. Pull the bonnet down over the studs. 12. Hand tighten the bonnet nuts. 13. Ensure that the gate is not on the bottom of the cavity. 14. Evenly tighten the bonnet nuts. (See Table IX.)

Note: The raised bonnet face on valves 10,000 psi and above will fully contact the body face when the bonnet nuts are tight.
Table IX: Recommended Bonnet Stud Torque
Valve Size 113/16" 10,000 113/16" 15,000 21/16" 2000 21/16" 3000/5000 21/16" 10,000 21/16"15,000 29/16" 2000 29/16" 3000/5000 29/16" 10,000 29/16"15,000 31/8" 2000 31/8" 3000 31/8" 5000 31/16" 10,000 31/16" 15,000 41/16" 2000 41/16" 3000 41/16" 5000 41/16" 10,000 51/8" 5000 51/8" 10,000 61/8"/63/8" 2000 61/8"/63/8" 3000 61/8"/63/8" 5000 Bonnet Stud Size - TPI 1.125-8 1.250-8 .625-11 .875-9 1.125-8 1.250-8 .750-10 1.000-8 1.250-8 1.500-8 .750-10 .875-9 1.125-8 1.250-8 1.500-8 .875-9 1.125-8 1.250-8 1.625-8 1.375-8 1.375-8 1.000-8 1.125-8 1.375-8 Recommended Stud Torque ft-lb (Nqm) 675(915) 950(1290) 115(160) 300(410) 675(915) 950(1290) 200(270) 475(645) 950(1290) 1675(2270) 200(270) 300(410) 675(915) 950(1290) 1675(2270) 300(410) 675(915) 950(1290) 2150(2915) 1275(1730) 1275(1730) 475(645) 675(915) 1275(1730)

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VIII. ORDERING REPLACEMENT PARTS The only information needed for ordering replacement parts for a Cameron gate valve is the original valve assembly part number and the description of the part. The valve assembly part number is stamped on the valve body nameplate. It is recommended that a description of the valve assembly (size, pressure, trim) be included as a check on the assembly number, but this is not necessary if the assembly number is clearly readable. It is not recommended to order replacement parts by using the part number off the old part or by referring to a file copy of the valve assembly bill-of-material. If an engineering change has been implemented to the valve assembly to replace one component part number with another, the only way to ensure getting the updated component is to reference the valve assembly number and to reference the part by description (gate, seat, stem, etc. Part descriptions are shown in the parts list, Part I.D.). Cameron personnel can then check the latest revision of the assembly bill-of-material to obtain the appropriate and current replacement part number.

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