F and FC Gate Valves Operation and Maintenance Manual @ CAMERON c1083@ CAMERON Al the information contained in this manual is the exclusive property of Cooper ‘Cameron Corporation, Cameron Division. Any reproduction or use of the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is {forbidden without the written permission of Cameron or its authorized agent. Initial Release At October 1994 Revsion By February 1996 Copyright © 1998 all rights reserved by Cooper Cameron Corporation, Cameron Division@ CAMERON CONTENTS Preface eee teens 5 |. Periodic Maintenance «2... eee ee 7 A. Lubrication 6 eee eee 7 B. Lubrication Chart... eee ee 7 C. Body Cavity Lubrication 6... eee 8 D. Thrust Bearing Lubrication... 2... eee 9 I Troubleshooting ©... eee 9 Ill. Bonnet Grease Fitting Replacement... 0... ee eee ee . 10 A. Valves 5000 psi WP and Below .... beeen eee eee 10 B. Valves 10,000 psiWP and Above .... 2... 2.0.0.0 eee +. 10 IV. Stem Shear Pin and Thrust Bearing Replacement ........ veces 4 ‘A, Remove the Thrust Bearings... 0... eee " B. Install the New Thrust Bearings ©... eee ee 12 V. Stem Packing Replacement with Pressure inthe Valve... ........ vee 12 ‘A. Remove the Stem Packing... 26... eee eee ee 12 B. Install the New Packing. ©... 2. eee ee 15 VI. Gate and Seat Replacement... 2... eee 16 A. Gate and Seat Disassembly - Manual Valve... 2... eee eee 16 B. Gate and Seat Assembly -Manual Valve... 00.0... 00.02 e eee 17 ©. Gate and Seat Disassembly - Valves with Hydraulic Actuators .......... 19 D. Gate and Seat Assembly - Valves with Hydraulic Actuators... 2.2... 20 Illustrations and Parts Lists@ CAMERON PREFACE ‘This manual supersedes Cameron publication $D1520. ‘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. Filo 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 are accurate. SD numbers on drawings and photographs are for artwork identification only. Refer to ‘component part numbers in all communications concerning this equipment. Direct any questions concerning the information in this manual to the Valve Engineering Department. Direct requests for additional copies of this manual to the Technical Publications Department. Cameron P.O. Box 1212 Houston, Texas 77251-1212 Ph: 719/939-2211 Fax: 719/939-2620@ CAMERON F AND FC VALVE MAINTENANCE |, PERIODIC MAINTENANCE A. Lubrication 1, Recommended body cavity lubricant a. For normal operation, use Cameron standard valve grease, which is not affected by water or temperatures ranging from -20° to +250°F, b. For continuous service below 0°F, use one of the two available low temperature greases. ¢. For COz injection or very high CO2 production, use diesel-resistant grease. 4. For continuous service above 180°F, use one of the two available high temperature greases, e. Part numbers for ordering grease as well as selection guidelines are given in the Lubrication Selection Chart. 2. Recommended thrust bearing lubricant a. For normal operation use Cameron standard valve lubricant, which is not affected by water or temperatures ranging from -20° to +250°F. b. For continuous service below 0°F, use one of the two available low temperature greases. B. Lubrication Chart | Lubricant Volume | Lubricant Weight | Approximate Follower Bore Size | Pressure | “Required (cu in) (ib) Plate Travel (in) (in) | Rating 7 | | Fo F FC F FC Fassne | oan | 17 50 07 | 20 03 ow 2416 Al | 18 53 07 at 03 oy zens |to1000) 25 | a | 10 | a4 | o« | 98 296 | 15,000 | 36 5 | 15 | 54 o7 Es 3-1/8 | To 10,000/ 34 3 | 14 | 53 os | 33 31 | 15000 | 87 | 200 | 23 | 80 1.0 eS 4-18 | Tos000 52 | 270 | 21 | 108 09 et ei | 000 | 6s | as | 26 | ine | ta | 48 sve | 5000 | a5 | 455 | 34 | 182 15 oy 5-1/8 | 10,000 135 | s20 | 55 | 208 23 ao | 618 ar 175 | @50 | 70 260 | 30 | 4 3tiag | 63 AD] 738 - 315 : ao L7ne All - 1035, - 4nd :Lubrication Selection Chart Service Operational Quantities (By Part Number) Service Temperature | Properties | Available on a Standard Order Basis ] | goog | | 6 (3s | € € | | le) 5 3 2 2 | B| jas) 3 | «| a] | 8 | igisl/Ziz) ¢ & | ¢ 2 2 \s\Blgig) g | 2 | 2 3 | | jas/s/8) 2 | 2 | 2 | & | 8 | | -20°F to 250°F | T . |_ Standart | (2eteatre) E|P | | 7onv4o | 700867 | 7o0se| roses | 7osro -50°F to 250°F | | | tow |aPEIB see | P| | | root | roosrs | roosre | rooers | 7oosrs Temperature | 759% to 250°F | | | | (Bee EE ge fe | ri1027 |r1s027-|7110072|7110272|711027-4 t moter eo Diesel | O° to 360% | resistant | (4etCto 1770) | & ||| G | 719897 |719897-1 719897-2|719897-9|719807-4 t - | | 0°F 10.450°F | ign (IBtCwnae) ©] P/F P| r7 | nee | rocco | ones | reese Temperature | a5eF to 500°F ts — 4 (retaseere ||P | FP) 710196 [701941 rrore42|71010¢9| 7101044 E- Excellent (Recommended) |G Good (Recommended) C. Body Cavity Lubrication 1. Normal Operating Conditions Cameron lubricates gate valves on assembly. Lubricate the body cavity after the valve has been in service one month. 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, PIN 19873-01, connect the grease gun coupler to the grease fitting. P. F - Fair (Not recommended) oor (Not Recommended) * Available in 20 b pail only —_ c. Pump the appropriate amount of lubricant into the body cavity. See Part |, 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: a. Lubricate the valve body cavity before itis put into operation.b. Flush the valve with appropriate neutralizing fluid after it is removed from service. ¢. Operate the valve with fresh water or appropriate neutralizing fluid in the line. 4d. Lubricate the valve body cavity, D. Thrust Bearing Lubrication Lubricate the thrust bearings as otten 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. Il. TROUBLESHOOTING Problem | Gate and seat assembly is Fluid leaks past the gate and | worn. seat assembly. Replace the gate and seat assembly. | landvee icrotbackea on Baekofthe hardwheo 1 turn, valve | | Fluid leaks around the valve | stem packing is worn Replace the stem packing, | | Bamet seat ings wom Replace the bonnet seal ring. | Fluid leaks at the bonnet | Loose bonnet nuts. Relighten the bonnet bots. flange. Bonnet or body ring groove is | Return the valve to Cameron damaged. | for repair. Fluid leaks from the bonnet | Check valve inside the grease | | grease iting. L ting is wom. | Replace the gronse fting, | Thrust bearings have lost| Lubricate the thrust bearings. lubricant. | Replace the thrust bearings. Handwheel is hard to tum. Thrust bearings are corroded. | Lubricate the gate and stem Gate and stem threads have | through the bonnet grease lost lubricant. - fiting Handwheel tums without opening or closing the valve, ‘Stem shear pin is sheared. | Replace the stem shear pin.@ CAMERON lll, BONNET GREASE FITTING REPLACEMENT 1. A. Valves 5000 psi WP and Below [i bamewrpa Grease itn Backseat the valve. =). | cap Pressure» Pressure a. Close the valve fully. Prose, Pres b. Loosen the bearing cap = four complete turns using a 24" pipe wrench. Grease Fiting Body oo 2. 3. 4, c. Tum the handwheel clockwi@é*{fHe eiBeniy EERO; BAR 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. Test the effectiveness of the backseat. a. Remove the grease fitting cap. . 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, ©. Replace the cap slowly unti the ball in the fitting is unseated and the pressure trapped by the backseating process is released. d. If pressure escapes quickly, 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. Remove the grease fitting from the valve bonnet. Install a new grease fitting. B. Valves 10,000 psi WP and Above Note: These valves have a “buried” check valve beneath the bonnet grease fitting. 1 2. 3. Remove the grease fitting cap. Trip the ball in the grease fitting check valve by inserting a 1/8" diameter by 9/4" long pin into the run of the fitting. Replace the cap slowly until the ball in the fitting is unseated. If the trapped pressure escapes quickly, then stops, the “buried” check valve is holding pressure. a. Remove the grease fitting. 10b. Install a new grease fitting. 5. If pressure continues to escape, the “buried” check valve is leaking. a. Backseat the valve. 1) Close the valve fully. 2) Loosen the bearing cap four complete turns using a 24" pipe wrench. 3) Tum 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. 4) Bump the handwheel in the closing direction. b. Tighten the grease fitting cap to unseat the ball in the grease fitting check valve and release the trapped pressure, ¢. Remove the grease fitting 4d. Replace the “buried” check valve. 1) Remove the defective check valve using an Allen wrench. 2) Install a new check valve. e. Install a new grease fitting. IV. STEM SHEAR PIN AND THRUST BEARING REPLACEMENT The stem thrust bearings can be replaced while the valve is under pressure in the line. ‘A. Remove the Thrust Bearings 1. Loosen the bearing cap using a 24” pipe wrench. After two or three tums, the cap will rotate freely by hand. Caution: If the cap does not rotate freely after three tums, the packing gland may be moving outward with the bearing cap. Do not remove the cap. Tighten the cap and contact a Cameron representative. 2. Ifthe 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. Remove the adapter from the stem. Remove both sets of bearings and bearing races from the stem adapter. Discard any pitted, cracked, or damaged bearings or races. NOs Discard the stem adapter if either bearing surface on the adapter shoulder is damaged. "@ CAMERON B. Install the New Thrust Bearings 1. Remove the new bearings from the protective packaging. Pack the bearings with grease. Place each bearing between a pair of carefully cleaned races. Carefully clean the stem adapter. 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 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. ae eN 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 using a 24" wrench. 12. Rotate the stem adapter counterclockwise to ensure that the gate is off the bottom of the body. This will confirm that the stem backseating shoulder is not contacting the bonnet shoulder. 1. Inject grease through the bearing cap grease fittings until excess grease passes through the bleed port. V. STEM PACKING REPLACEMENT WITH PRESSURE IN THE VALVE ‘A. Remove the Stem Packing 1. Backseat the valve. a. Close the valve fully. b. Loosen the bearing cap four complete tums using a 24" pipe wrench. c. Tum 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.@ CAMERON 2. Test the effectiveness of the backseat. a. Valves 5000 psi WP and below. 1) Remove the bonnet grease fitting cap. 2) 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. 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, 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 10,000 psi WP and above. Note: These valves have a “buried” check valve beneath the bonnet grease fitting. 1) Remove the bonnet grease fitting cap. 2) 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. 3) Replace the cap slowly until the ball in the fitting is unseated and any trapped pressure is released. 4) If pressure escapes quickly, then stops, the “buried” check valve is holding pressure. Proceed to step 6). 5) If pressure continues to escape, the “buried” check valve is leaking and the backseat is ineffective. Backseat the valve again. Repeat steps 1 and 2. 6) Remove the grease fiting. 7) Remove the protective collar from the check valve unseating tool, P/N 20013-03 0” 2013-02. 8) Install the unseating tool in the bonnet grease fitting preparation. 9) Slowly tum the unseating tool clockwise until the ball in the “buried” check valve is unseated and the pressure trapped by the backseating process is released. 10) If pressure escapes quickly, then stops, the backseat is effective. Proceed to step 14). 13@ CAMERON 11) Ifo pressure escapes, the “buried” check valve is defective. Proceed to step 14). 12) If pressure continues to escape, the backseat is ineffective. Repeat steps 1 and 2. 18) If the backseat continues to be ineffective, contact a Cameron representative. 14) Remove the check valve unseating tool. 15) If the “buried” check valve is defective, replace it using an Allen wrench. 16) Reinstall the grease fitting. 3. Remove the handwheel and the bearing cap. > Remove the cap from the bonnet. a Using a punch, drive the stem shear pin from the stem adapter,ensuring that the adapter is not damaged, Remove the adapter from the stem. Remove both sets of bearings and bearing races from the stem adapter. Using a 24" pipe wrench, loosen the packing gland. Ensure that the threads on the bonnet neck OD are not damaged. Remove the packing gland. BSG BND Remove the stem packing. a. Use packing sleeve P/N 21168 for 1* stem size and P/N 23842 for 1-1/4" 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. Ifa packing sleeve is not available, remove the stem packing by one of the following methods: 1) Pump packing out with grease until grease by-passes or packing refuses to extract further. 2) Pull the packing out with a corkscrew. Caution: Do not damage the stem or packing bore. 4