Operation and Maintenance Manual

Manually Actuated
FL and FLS Gate Valves

TC148
 All the information in this manual is the exclusive property of Cooper
Cameron Corporation, Cameron Division. Any reproduction or use of
the calculations, drawings, photographs, procedures, or instructions, ei-
ther 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

Copyright 2005 all rights reserved

by
Cooper Cameron Corporation, Cameron Division

TC148 2
PREFACE
The procedures included in this book are to be performed in conjunction
with the requirements and recommendations outlined in API Specifica-
tions. 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 termi-
nate 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 Cameron products, which are products of Cooper

Cameron Corporation.

Cooper Cameron Corporation

Cameron Division
P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.coopercameron.com

TC148 3
TC148 4
Table Of 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 . . . . . . . . . . . . . . . . . . 15

A. Valves 10,000 psi and Below . . . . . . . . . . . . . . . . . . . 15

B. Valves 15,000 psi 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 . . . . . . . . . . . . . 18

VI. Stem Packing Replacement With Pressure In The Valve . . . . . . . 19

A. Removal of the Stem Packing . . . . . . . . . . . . . . . . . . 19

B. Installation of the New Packing . . . . . . . . . . . . . . . . . 21

VII. Gate and Seat Replacement . . . . . . . . . . . . . . . . . . . . . . 23

A. Gate and Seat Disassembly . . . . . . . . . . . . . . . . . . . . 23

B. Gate and Seat Inspection . . . . . . . . . . . . . . . . . . . . . 23
C. Gate and Seat Assembly . . . . . . . . . . . . . . . . . . . . . 24

VIII. Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . 27

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TC148 6
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 avail-
able in standard double flange, threaded-end, and special block body con-
figurations. 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 sim-
plify field service. The modified Acme gate-to-stem thread allows the
gate to move back and forth, or float, to seal against the seat.

3. The gate and seat assembly seals in both directions, and the gate and
seats can be reversed for increased life.

4. The stem shoulder can be back seated against the bonnet to isolate
the stuffing box, which allows field-replacement of the stem packing
while the valve is under pressure.

5. The non-rising stem prevents a cavity pressure increase or displace-

ment 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 lubri-
cant ports extend directly into the valve cavity.

7. The seal between the valve body and bonnet is a pressure-energized,

BX-style metal bonnet gasket on 10,000 and 15,000 psi WP valves.
Valves for 3000 and 5000 psi WP use a flat compression-type metal
gasket.

8. API 6A Materials Classes and Temperature Classes are available, and

other special trims area available upon request. Reduced-hardness
bonnet bolting can be supplied for most sizes and pressures without
downrating the working pressure.

9. With minor modifications, FL and FLS valves can meet or exceed API
6FA fire safety requirements.

TC148 7
 10. Special non-elastomeric stem packing designs can extend the standard
temperature rating of the FL or FLS Gate Valve up to 350o F (180oC), or
down to -75o F (-60oC). These temperature ratings may not be avail-
able in all working pressures.

11. An optional add-on torque multiplier is available for larger FL and FLS
valves to provide easier operation.

12. See the valve assembly bill-of materials for materials and descriptions
of valve components.

B. Operation Instructions
A gate valve should always be in either the full-open or full-closed posi-
tion. 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 turn will
then relieve any stress in the stem, and is, therefore, recommended prac-
tice. 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) to turn. The num-
ber of turns required to move the valve from full open to full closed is
given in Table I.

Table I: Operating Requirements

2000 - 3000 psi WP 5000 psi WP

Valve Bore Size - 2-1/16 2-9/16 3-1/8 4-1/16 5-1/8 6-3/8 2-1/16 2-9/16 3-1/8 4-1/16 5-1/8 6-3/8
Inch
Expected Opening
Torque, Lubricated 15 20 25 30 45 80 20 25 35 50 75 140
Valve, ft-lb
Maximum Opening
Torque, Severe 30 40 60 80 130 235 45 65 95 135 220 395
Service, ft-lb
Total Number of
Turns, 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
Full-Open to
Full-Close

10,000 psi WP 15,000 psi WP

Valve Bore Size - Inch 1-13/16 2-1/16 2-9/16 3-1/16 4-1/16 5-1/8 1-13/16 2-1/16 2-9/16 3-1/16
Expected Opening
Torque, Lubricated 30 35 50 65 110 260* 50 60 100 125
Valve, ft-lb
Maximum Opening
Torque, Severe 80 85 130 170 320 690* 125 155 265 335
Service, ft-lb
Total Number of
Turns, 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
Full-Open to
Full-Close

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

TC148 8
 C. Dimensional Data

Table II: Dimensional Data - 2000 psi WP

Item Description 2-1/16 2-9/16 3-1/8 4-1/8 6-1/8

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

Center of Port to Top of Stem 13 33-13/16 16-13/16 18-7/16 22-3/4
C Adapter
D Center of Port to Bottom of Body 5-1/4 6 7-1/8 9-1/8 12-7/8
Center of Port to Top of Handwheel 15-3/8 16-1/8 19-1/16 20-11/16 24
E Rim
F Handwheel OD 14 14 14 14 18-1/2

Weight (Flanged) 160 lb 200 lb 240 lb 350 lb 800 lb

Table III: Dimensional Data - 3000 psi WP

Item Description 2-1/16 2-9/16 3-1/8 4-1/8 5-1/8" 6-1/8
A End-to-End, Threaded 10-5/8 12-3/8 13-5/8
A End-to-End, 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 13 33-13/16 16-13/16 18-7/16 21-5/16" 22-3/4

Adapter
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 15-3/8 16-1/8 19-1/16 20-11/16 22-9/16 24

Handwheel Rim
F Handwheel OD 14 14 14 18-1/2 24 24
Weight (Flanged) 170 lb 220 lb 260 lb 450 lb 750 lb 1000 lb

TC148 9
Table IV: Dimensional Data - 5000 psi WP

Item Description 2-1/16 2-9/16 3-1/8 4-1/8 5-1/8" 6-1/8

A End-to-End, Threaded 10-5/8 12-3/8 13-5/8

A End-to-End, Flanged (Ring 14 -5/8" 16 -5/8" 18 -5/8 21-5/8 28-5/8 29

Joint)
A End-to-End, Butt Weld 21-1/2
B Extreme Width of Body 7 8-3/16 9-1/4 10-13/16 21-3/4 14-1/8

C Center of Port to Top of 15-1/8 15-15/16 16-13/16 18-7/16 21-5/16" 22-3/4

Stem Adapter

D Center of Port to Bottom of 5-5/8 6-1/2 7-3/8 9-1/8 11-3/8 12-7/8

Body

E Center of Port to Top of 17-3/8 18-1/8 19-1/16 20-11/16 23-9/16 24

Handwheel Rim
F Handwheel OD 14 14 18-1/2 18-1/2 24 24
Weight (Flanged) 175 lb 230 lb 360 lb 520 lb 800 lb 1160 lb

Table V: Dimensional Data - 10,000 psi WP

Item Description 1-13/16 2-1/16 2-9/16 3-1/16 4-1/16 5-1/8

A End-to-End, Flanged (Ring 18-1/4 20-1/2 22-1/4 24-3/8 26-3/8 29

Joint)
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 15-1/8 15-1/8 15-13/16 16-7/8 19-11/16 23-7/8

Stem Adapter

D Center of Port to Bottom of 5-3/4 5-7/8 6-13/16 8-1/16 10-1/16 13-1/8

Body

E Center of Port to Top of 17-3/8 17-3/8 18-1/8 18-1/16 20-15/16 25-1/4

Handwheel Rim
F Handwheel OD 14 18-1/2 18-1/2 24 24 24
Weight (Flanged) 250 lb 275 lb 370 lb 480 lb 880 lb 1750 lb

Table VI: Dimensional Data - 15,000 psi WP

Item Description 1-13/16 2-1/16 2-9/16 3-1/16

A End-to-End, Flanged (Ring 18 19 21 23-9/16

Joint)
B Extreme Width of Body 9-7/8 9-7/8 11-1/2 13-9/16

C Center of Port to Top of Stem 15-1/8 15-1/8 17-3/16 20-15/16

Adapter

D Center of Port to Bottom of 5-7/8 6-1/8 7-5/16 9-1/4

Body

E Center of Port to Top of 17-3/8 17-3/8 19-9/16 22-3/16

Handwheel Rim
F Handwheel OD 18-1/2 18-1/2 18-1/2 24
Weight 275 lb 300 lb 560 lb 890 lb

TC148 10
 D. Parts List

TC148 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 (-29oC to 121oC).

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 (-29oC to 121oC).

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 Pressure Lubricant Volume Lubricant Weight Approximate Follower

(in.) Rating Required (cu in.) (lb) Plate Travel (in.)
1-13/16" All 38 1.5 .5
2-1/16 All 43 1.7 .7
2-9/16" To 10,000 79 3.2 1.3
2-9/16" 15,000 93 3.7 1.6
3-1/8 To 5000 114 4.6 1.9
3-1/16 10,000 114 4.6 1.9
3-1/16 15,000 155 6.2 2.6
4-1/8 To 5000 245 9.8 4.2
4-1/16 10,000 243 9.7 4.1
5-1/8 5000 312 12.5 5.3
5-1/8 10,000 461 18.5 7.8
6-1/8 To 5000 583 23.3 9.9
6-3/8 To 5000 583 23.3 9.9

TC148 12
Table VIII: Lubricant Selection

Lubricant Quantities (By Part Number)

Service Operational Properties Solvent
Name Available on a Standard Order Basis

With H2S (Sour Crude or Gas)

With Gas Well Condensates

High Temp. RT to +650oF
Low Temp. to -75oF
Standard Crude

Very High CO2

120 lb. Drum

400 lb. Drum

(Per Pound)

25 lb. Pail
5 lb. Can
Diesel

Standard CI-14 or E P P P F F P Mineral 700149 700667 700668 700669 700670

TF-41 Spirits

Arctic NS-14 E E P P F F P Mineral 700123 700671 700672 700673 700674

Spirits
Diesel SS-14 or E P E P G G G Alcohol 700150 700675 700676 700667 700678
Resistant TS-41
High HT-14S G F P E F F P Mineral 700217 700679 700680 700681 700682
Temp Spirits
High Moly 101 G P P E G F P Mineral 710194 700679 700680 700681 700682
Temp Spirits
E - Excellent F - Fair
G - Good P - Poor Example For Ordering: Order Part Number 700672 for 25 lb. of NS-14

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.

TC148 13
 2. Unusual Temporary Operating Conditions

If it becomes necessary to cement through, acidize through, or subject

the valve to any other unusual service, proceed as follows:

a. Lubricate the valve body cavity before it is put into operation.

b. Flush the valve with the appropriate neutralizing fluid in the line.

c. Operate the valve with fresh water or appropriate neutralizing

fluid in the line.

d. Lubricate the valve body cavity.

D. Thrust Bearing Lubrication

Note: Lubricate the thrust bearings as often as required to ensure smooth valve
operation.

1. Using a hand-held grease gun, P/N 19873-01, connect the grease gun
fitting to the hydraulic grease fittings with a hydraulic coupler.

2. Pump lubricant into the fittings until clean grease appears at the
bleed port on the opposite side of the bearing cap.

III. Troubleshooting
Symptom Cause
1. Gate or seats are worn.
Fluid leaks past the gate
and seat assembly. 2. Handwheel is not backed off.
Fluid leaks around the Stem packing is worn.
valve stem.
1. Bonnet seal ring is worn.
Fluid leaks at the bonnet
flange. 2. Bonnet or body ring groove
oois damaged.
Fluid leaks from the Check valve inside the grease
bonnet grease fitting. fitting is worn.
1. Thrust bearings have lost
oolubricant.
Action
Replace the gate or seats.
Back off the handwheel
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.

Handwheel is hard to turn. Replace the thrust bearings.

2. Thrust bearings are corroded.
Lubricate the gate and stem
3. Gate and stem threads have through the bonnet grease
oolost lubricant. fitting.
Handwheel turns without
opening or closing the Stem shear pin is sheared. Replace the stem shear pin.
valve.

TC148 14
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, pre-
cautions 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.

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 out-
ward, 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.

b. Trip the ball in the grease fitting

check valve by inserting a 1/8 di-
ameter by long pin into the
run of the fitting.

c. Replace the cap slowly until the

ball in the fitting is unseated and
the pressure trapped by the
backseating process is released.

d. If pressure escapes quickly and then stops, the backseat is effective.

Proceed to step 3.

e. If pressure continues to escape, the backseat is ineffective.

1) Backseat the valve again. Repeat steps 1 and 2.

TC148 15
 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

(33 Nm).

b. Turn the handwheel counterclockwise (opening direction) one full

turn while simultaneously tightening the bearing cap.

c. Tighten the bearing cap to approximately 200 ft-lb (270 Nm).

B. Valves 15,000 psi WP and Above

Note: The standard grease fitting for 15,000 psi WP FL valves is a special metal-seal-
ing, high pressure fitting, containing a check valve. The bonnet port hous-
ing this fitting is a special preparation without pipe threads which accepts
only this type of fitting.

Important: DO NOT use Teflon tape or thread

sealant on these fittings.

1. Backseat the valve.

a. Close the valve fully.

b. Loosen the bearing cap four

complete turns.

c. Turn the handwheel clockwise

(the closing direction) until the
gate firmly 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.

TC148 16
 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 un-
seats 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.

4. Remove the cap from a new grease fitting and install the fitting in the
bonnet. Torque to 80 to 100 ft-lb (100 to 135 Nm).

5. Install and tighten the cap on the fitting.

Caution: Installing the fitting with the cap in place prevents the fitting from seat-
ing and could cause damage to the cap. Do not install the fitting with
the cap in place.

6. Un-backseat the valve.

a. Tighten the bearing cap. Torque to approximately 25 ft-lb

(33 Nm).

b. Turn the handwheel counterclockwise (opening direction) one full

turn while simultaneously tightening the bearing cap.

c. Tighten the bearing cap to approximately 200 ft-lb (270 Nm).

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.

TC148 17
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 tap-
ping 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, ensur-
ing that the adapter is not damaged.

4. Remove the adapter from the stem. Remove both sets of bearings
and bearing races from the stem adapter.

5. Discard any pitted, cracked, or damaged bearings or races.

6. Replace the stem adapter if either of the bearing surfaces on the

adapter shoulder is damaged.

B. Installation of the New Thrust Bearings.

1. Remove the new bearings from the protective packaging.

2. Pack the bearings with clean grease.

3. Place each bearing between a pair of carefully cleaned races.

4. Carefully clean the stem adapter.

5. Install one set of bearings and races over the bottom of the adapter
and one set over the top of the adapter.

Note: The adapter O-ring may be removed temporarily to allow for the installation
of the top bearing and race assembly.

6. Insert the stem adapter over the end of the stem and align the pin
hole in the adapter with the hole in the stem.

7. Using a punch, drive in the stem pin and ensure that the pin does not
protrude over the OD of the adapter shoulder.

Caution: Do not strike the bearings, races, or stem adapter with the punch or
hammer.

8. Replace the stem adapter O-ring if necessary.

9. Inspect the bearing cap to ensure that an extra race, held by grease
tension, is not retained inside.

TC148 18
 10. Clean the bearing cap and lubricate the threads.

11. Install the cap, and tighten to approximately 200 ft-lb (270 Nm).

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

1. Backseat the valve.

a. Close the valve fully.

b. Loosen the bearing cap four complete turns.

c. Turn the handwheel clockwise (the closing direction) until the gate
firmly contacts the bottom of the cavity and the stem moves out-
ward, contacting the internal backseat shoulder.

d. Bump the handwheel in the closing direction.

2. Backseat the valve.

a. Valves 10,000 psi WP and Below. Refer to Figure 3.

1) Remove the bonnet grease fitting cap.

2) Trip the ball in the grease fitting check valve by inserting an 1/8
diameter by long pin into the run of the fitting.

3) Replace the cap slowly until the ball in the fitting is unseated
and the pressure trapped b the backseating process is released.

4) If pressure escapes quickly and then stops, the backseat is effec-

tive. Proceed to step 3.

5) If pressure continues to escape, the backseat in ineffective.

a) Backseat the valve again. Repeat steps 1 and 2.

TC148 19
 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 un-
seats the metal seal and vents any pressure on the fitting.

3) If pressure escapes quickly and then stops, the backseat is effec-

tive. Proceed to step 3.

4) If pressure continues to escape, the backseat in ineffective.

a) Backseat the valve again. Repeat steps 1 and 2.

b) If the backseat continues to be ineffective, contact a

Cameron representative.

3. Remove the handwheel and bearing cap.

4. Remove the cap from the bonnet.

5. Using a punch, drive the stem shear pin from the stem adapter, ensur-
ing that the adapter is not damaged.

6. Remove the adapter from the stem.

7. Remove both sets of bearings and bearing races from the stem
adapter.

8. Loosen the packing gland.

9. Ensure that the threads on the bonnet neck OD are not damaged.

10. Remove the packing gland.

11. Remove the stem packing and backup ring (if applicable).

a. Use packing sleeve P/N 21168 for 1 stem size and packing sleeve
P/N 233842 for 1 stem size.

1) Thread the packing sleeve into the bonnet packing gland prepa-
ration 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.

TC148 20
 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 hydraulic lock will
not prevent the installation of new packing.

2. Inspect the stuffing box to ensure that the bore is clean and free of
pits or scars.

3. Inspect the stem to ensure that the surface is free of burrs and pits.

4. Apply a light coat of grease to:

a. The stem.

b. The stuffing box bore.

c. The ID and OD of the stem packing.

d. The nose and threads of the packing gland.

5. Lightly grease the new stem packing. Install it over the stem and into
the bonnet as follows:

a. J packing or U packing: Install with rounded nose facing pressure.

b. Varipak or SLS packing: Install with open-end facing pressure.

c. HT-20 packing: Call Cameron service. (Special tools required; not

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.

TC148 21
 8. Install the packing gland and apply approximately 200 ft-lb (270 Nm)
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.

18. Clean the bearing cap and lubricate the threads.

19. Install the cap, and torque to 200 ft-lb (270 Nm).

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.

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VII. Gate and Seat Replacement

A. Gate and Seat Disassembly

1. Isolate the valve from the line pressure.

2. Release the cavity pressure by bleeding the cavity pressure through

the bonnet grease fitting.

3. With the bonnet grease fitting still vented, stroke the valve one com-
plete cycle, ending in the full open position.

Caution: Any trapped pressure will be vented through the bonnet grease fitting
or end flange.

4. Remove all bonnet nuts.

5. 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
seat and pry the seat out.

9. Flush the body cavity thoroughly with suitable solvent and wipe clean
with a rag.

B. Gate and Seat Inspection

1. Inspect the cavity parts for damage.

a. Ensure that the retainer plate is not bent, twisted, or distorted.

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

b. Ensure that the seal rings are not damaged.

c. Ensure that the seats are not cut or damaged.

d. Ensure that the gate is not cut or damaged.

2. Replace any damaged parts.

TC148 23
 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 bot-
tom, 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 re-
maining space with grease.

5. Remove the seal ring from the bonnet groove.

6. Clean the grooves and/or seating area of the body and bonnet.

7. Apply a very thin film of clean grease to the bonnet seal ring and
groove.

8. Install the new seal ring in the bonnet groove.

9. Install the bonnet over the body studs.

a. On valves 5000 psi WP and below, rotate the bonnet so that the
bonnet locating pins in the body align with the pinholes in the
bonnet.

b. On valves 10,000 psi WP and above, rotate the bonnet until the
grease fitting is 90 from the gate bore.

10. Thread the stem into the gate by turning the handwheel counter-
clockwise.

TC148 24
 11. Pull the bonnet down over the studs.

12. Hand tighten the bonnet nuts.

13. Ensure that the gate is not on the bottom of the cavity.

14. Evenly tighten the bonnet nuts. (See Table Below.)

Note: The raised bonnet face on valves 10,000 psi and above will fully contact the
body face when the bonnet nuts are tight.

Recommended Makeup Torques, Ft-Lbf

Per API 6A: Preload = .50Sy
English Units
B7M, L7M (80 ksi) B7, L7, 660 (105 ksi)
Bolt Size Xylan or Xylan or
Nom OD - TPI Sermagard Zinc Plated Sermagard Zinc Plated
Coated or Uncoated Coated or Uncoated
.625-11 52 88 68 115
.750-10 90 153 118 200
.875-9 143 243 188 319
1.000-8 213 361 279 474
1.125-8 305 523 401 686
1.250-8 421 726 553 953
1.375-8 563 976 739 1280
1.500-8 733 1280 962 1680
1.625-8 934 1640 1230 2150

Recommended Makeup Torques, Nm

Per API 6A: Preload = .50Sy
Metric Units
B7M, L7M (80 ksi) B7, L7, 660 (105 ksi)
Bolt Size Xylan or Xylan or
Nom OD - TPI Sermagard Zinc Plated Sermagard Zinc Plated
Coated or Uncoated Coated or Uncoated
.625-11 70 118 92 155
.750-10 122 206 160 270
.875-9 193 328 253 429
1.000-8 288 488 376 639
1.125-8 413 706 540 925
1.250-8 569 981 745 1290
1.375-8 761 1320 996 1730
1.500-8 991 1730 1300 2270
1.625-8 1260 2210 1660 2910

TC148 25
TC148 26
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 as-
sembly 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-ma-
terial. If an engineering change has been implemented to the valve assembly
to replace one component part number with another, the only way to ensure
getting the updated component is to reference the valve assembly number
and to reference the part by description (gate, seat, stem, etc. Part descrip-
tions are shown in the parts list, Part I.D.). Cameron personnel can then
check the latest revision of the assembly bill-of-material to obtain the
appropriate and current replacement part number.
The replacement parts list included in this manual contain part numbers for
Cameron FL manual and surface actuated failsafe gate valves manufactured
prior to API 6A 15th Edition (1986), operating in the temperature ranges be-
tween -20 and 250oF (-29 and 121o C).

Contact your Cameron representative for replacement parts for FLS and all
other FL gate valves.

TC148 27
 Figure 1
FL MANUAL GATE VALVE
ALL EXCEPT 3-1/16 15,000 PSI WP

TC148 28
 FIGURE 2
FL MANUAL GATE VALVE
3-1/16 15,000 PSI WP

TC148 29
 FIGURE 3
FL GATE VALVE PREPPED FOR ACTUATOR
ALL SIZES AND PRESSURES

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