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Appendix-3-O&M Manual-Manually PDF
Appendix-3-O&M Manual-Manually PDF
Manually Actuated
Cameron FL and FLS Gate Valves
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All the information in this manual is the exclusive property of Cameron
International Corporation. Any reproduction or use of the calculations,
drawings, photographs, procedures, or instructions, either expressed or
implied, is forbidden without the expressed written permission of
Cameron or its authorized agent.
Initial Release A1
April 1992
Revision B1
April 1994
Revision C1
June 1997
Revision D1
June 2005
Revision E1
February 2007
Revision F1
March 2008
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PREFACE
The procedures included in this book are to be performed in conjunction
with the requirements and recommendations outlined in API 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.
Cameron
P.O. Box 1212
Houston, Texas 77251-1212
713-939-2211
http://www.c-a-m.com
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Table Of Contents
I. General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
B. Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . . 12
C. Body Cavity Lubrication . . . . . . . . . . . . . . . . . . . . . . 13
D. Thrust Bearing Lubrication . . . . . . . . . . . . . . . . . . . . 14
III. Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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I. General Information
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.
9. With minor modifications, FLS valves can meet or exceed API 6FA fire
safety requirements.
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10. Special non-elastomeric stem packing designs can extend the standard
temperature rating of the FL or FLS Gate Valve up to 350o F (180oC), or
down to -75o F (-60oC). These temperature ratings may not be 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 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.
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C. Dimensional Data
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Table IV: Dimensional Data - 5000 psi WP
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D. Parts List
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II. Periodic Maintenance
A. Lubrication
1. Recommended body cavity lubricant.
c. For continuous service above 180o F, use one of the two available
high temperature greases.
B. Lubrication Charts
Table VII: Grease Volume Requirements
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Table VIII: Lubricant Selection
Standard Crude
120 lb Drum
400 lb Drum
(Per Pound)
25 lb Pail
With H2S
5 lb Can
Diesel
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.
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2. Unusual Temporary Operating Conditions
b. Flush the valve with the appropriate neutralizing fluid in the line.
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 Action
1. Gate or seats are worn. Replace the gate or seats.
Fluid leaks past the gate
and seat assembly. 2. Handwheel is not backed off. Back off the handwheel
turn.
Fluid leaks around the Stem packing is worn. Replace the stem packing.
valve stem.
1. Bonnet seal ring is worn. Replace the bonnet seal ring.
Fluid leaks at the bonnet
flange. 2. Bonnet or body ring groove Return the valve to Cameron
oois damaged. for repair.
Fluid leaks from the Check valve inside the grease Replace the grease fitting.
bonnet grease fitting. fitting is worn.
1. Thrust bearings have lost Lubricate the thrust
oolubricant. bearings.
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Caution: When a valve is used in the lower master valve position, on the outlet of
a BOP or any other application in which it is the last surface barrier, 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 stem pin
replacement consideration should be given with respect to number of
barriers required by the customer and the local statutory requirements.
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.
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2) If the backseat continues to be ineffective, contact a Cameron
representative.
Caution: Installing the fitting with the cap in place could damage the cap. Do not
install the fitting with the cap in place.
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a. Remove the grease fitting cap.
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).
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.
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Caution: If the cap does not rotate freely after three turns, the packing gland may
be moving outward with the bearing cap. This can be checked by 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 pin from the stem adapter, ensuring
that the adapter is not damaged.
4. Remove the adapter from the stem. Remove both sets of bearings
and bearing races from the stem adapter.
5. 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.
9. Inspect the bearing cap to ensure that an extra race, held by grease
tension, is not retained inside.
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10. Clean the bearing cap and lubricate the threads.
11. Install the cap, and tighten to approximately 200 ft-lb (270 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.
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.
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.
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b) If the backseat continues to be ineffective, contact a
Cameron representative.
5. Using a punch, drive the stem pin from the stem adapter, ensuring
that the adapter is not damaged.
7. Remove both sets of bearings and bearing races from the stem
adapter.
9. Ensure that the threads on the bonnet neck OD are not damaged.
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.
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3) Remove the sleeve from the bonnet.
1) Pump the packing out with grease until the grease bypasses or
the packing refuses to extrude further.
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.
a. The stem.
5. Lightly grease the new stem packing. Install it over the stem and into
the bonnet as follows:
6. Using the packing gland as a pushing tool, push the packing into the
stuffing box.
7. Remove the packing gland and lubricate the stem OD. If a packing
back-up ring is required, install it over the stem.
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8. Install the packing gland and apply approximately 200 ft-lb (270 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.
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.
17. Inspect the bearing cap to ensure that an extra race, held by grease
tension is not retained inside.
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.
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VII. Gate and Seat Replacement
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.
5. Support the bonnet and turn the handwheel clockwise until the stem
completely backs out of the gate.
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.
Important: Solid material should not be built up on the retainer plate surfaces.
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3. Ensure that the body cavity is free of all foreign matter such as solid
particles, grit, trash, etc.
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.
Note: The FL valve uses one seal ring per seat; the FLS uses two per seat.
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.
4. Push the gate all the way to the bottom of the cavity and pack the re-
maining space with grease.
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.
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.
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11. Pull the bonnet down over the studs.
13. Ensure that the gate is not on the bottom of the cavity.
Note: The raised bonnet face on valves 10,000 psi and above will fully contact the
body face when the bonnet nuts are tight.
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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 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.
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Figure 1
FL MANUAL GATE VALVE
ALL EXCEPT 3-1/16 15,000 PSI WP
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FIGURE 2
FL MANUAL GATE VALVE
3-1/16 15,000 PSI WP
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FIGURE 3
FL GATE VALVE PREPPED FOR ACTUATOR
ALL SIZES AND PRESSURES
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