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Gate Valve

Description

MCM OIL TOOLS 9217 SUMMERBELL LANE HOUSTON,

TX 77074 Phone (713) 541-1212 Fax (713) 541-4664 [email protected] API 6A CERTIFIED

6A-0566

CAMERON® TYPE ‘FC’ GATE VALVE MANUAL AND HYDRAULIC MAINTENANCE MANUAL

GENERAL MAINTENANCE A

Body Cavity Lubrication 1

Normal Operating Conditions MCM lubricates gate valves when assembled

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

Remove the grease fitting cap located on the bonnet flange OD b

Using either a bucket type gun,

connect the grease gun coupler to the grease fitting

Pump the appropriate amount of lubricant into the body cavity

Unusual Temporary Operating Conditions If it becomes necessary to cement through,

or subject the valve to any other unusual services: a

Lubricate the valve body cavity before it is put into operation

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

Lubricate the valve body cavity

Thrust Bearing Lubrication Lubricate the thrust bearings as often as required to ensure smooth valve operation

Using a grease gun,

connect the grease gun fitting to the hydraulic grease fitting with a hydraulic coupler

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

TROUBLESHOOTING PROBLEM

SOLUTION

Fluid leaks past the gate and seat assembly

Gate and seat assembly are worn

Replace the gate and seat assembly

Back off the hand-wheel ¼ turn

Fluid leaks around the valve stem

Hand-wheel is not backed off

Stem packing is down

Fluid leaks at the bonnet flange

Bonnet seal ring is worn

Replace the bonnet seal ring

Loose bonnet nuts

Retighten the bonnet nuts

Body ring groove is damaged

Check valve inside the grease fitting is worn

Return the valve to MCM for repair

Replace the grease fitting

Fluid leaks from the bonnet grease fitting

Hand-wheel is hard to turn

Hand-wheel turns without opening or closing the valve

Replace the stem packing

Thrust bearings have lost lubricant

Lubricate the thrust bearings

Thrust bearings are corroded

Replace the thrust bearings

Gate and stem threads have lost lubricant

Stem shear pin is sheared

Lubricate the gate and stem through the bonnet grease fitting

Replace the stem shear pin

BONNET GREASE FITTING REPLACEMENT A

Valve 5000 PSI WP below 1

Backseat the valve a

Close the valve fully

Loosen the bearing cap four complete turns using a 24” pipe wrench

Turn the hand-wheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity and the stem moves outward contacting the internal backseat shoulder

Bump the hand-wheel in the closing directions

Test the effectiveness of the backseat

Remove the grease fitting cap

Trip the ball in the grease fitting check valve by inserting a •” diameter by ¾” long pin into the run of the fitting

Replace the cap slowly until the ball in the fitting is unseated and the pressure trapped by the backseating process is released

If pressure escapes quickly,

Proceed to step 3

If pressure continues to escape,

Repeat step 1 and 2

Remove the grease fitting from the valve bonnet

Install a new grease fitting

Valve 10,000 PSI WP and Above NOTE: These valves have a “buried” check valve beneath the bonnet grease fitting

Remove the grease fitting cap

Trip the ball in the grease fitting check valve by inserting •” diameter by ¾” 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,

the “buried” check valve is holding pressure

Remove the grease fitting b

Install a new grease fitting

If pressure continues to escape,

the “buried” check valve is leaking

Backseat the valve 1) Close the valve fully

Tighten the grease fitting cap to unseat the ball in the grease fitting check valve and release the trapped pressure

Remove the grease fitting

Replace the “buried” check valve

Install a new grease fitting

STEM SHEAR PIN AND THRUST BEARING REPLACEMENT The stem thrust bearings can be replaced while the valve is under pressure in the line

Remove the Thrust Bearing 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

Do not remove the cap

Tighten the cap and contact MCM

If the bearing cap rotates freely,

remove the cap from the bonnet

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 bearing and bearing races from the stem adapter

Discard any pitted,

Discard the stem adapter if either bearing surface on the adapter shoulder is damaged

Install the New Thrust Bearings 1

Remove the new bearings from the protective packaging

Pack the bearing 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

Insert the stem adapter over the end of the stem,

and align the pin hole in the adapter with the hole in the stem

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 bearing,

or stem adapter with a punch or hammer

Replace the stem adapter O-ring if necessary

Inspect the bearing cap to ensure that an extra race,

Clean the bearing cap and lubricate the threads

Install the cap using a 24” wrench

Rotate the stem adapter counterclockwise to ensure that the gate is at the bottom of the body

This will confirm that the stem back seating shoulder is not contacting the bonnet shoulder

Inject grease through the bearing cap grease fittings until excess grease passes through the bleed port

STEM PACKING REPLACEMENT WITH PRESSURE IN THE VALVE A

Remove the stem packing 1

Backseat the valve

Close the valve fully

Loosen the bearing cap four complete turns using a 24” pipe wrench

Turn the hand-wheel clockwise (the closing direction) until the gate firmly contacts the bottom of the cavity,

and the stem moves outward contacting the internal backseat shoulder

Bump the hand-wheel in the closing direction

Test the effectiveness of the backseat

Valves 5000 PSI WP and below

Proceed to step 3

Repeat steps 1 and 2

b) If the backseat continues to be ineffective,

Valve 10,000 PSI WP and above 5

Note: These valves have a “buried” check valve beneath the bonnet grease fitting

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 step 1 and 2

the “buried” check valve is defective

Proceed to step 14

Proceed to step 14

replace it using an Allen wrench

Remove the hand-wheel and the bearing cap 4

Remove the cap from the bonnet 5

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,

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

Remove the packing gland

Remove the stem packing

Use Packing sleeve appropriate for your stem,

whether 1” or 1-1/4” stem size

pump the packing out into the recessed area of the packing sleeve

If a 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

Caution: Do not damage the stem or packing bore

Install 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

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

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

Apply a light coat of grease to the stem,

and the ID and OD of the stem packing

Install the new packing over the end of the stem so that the rounded Teflon® nose of the packing faces the pressure

Using the packing gland as a pushing tool,

push the packing into the stuffing box

Remove the packing gland and lubricate the stem OD

Install the packing gland with a 24” pipe wrench

Apply approximately 200 ft-lb of torque,

ensuring that the bonnet threads are not damaged

Inspect the bearing and bearing races on the stem adapter for pits,

Replace if damages

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

Insert the stem adapter over the end of the stem,

and align the pin hole in the adapter with the hole in the stem

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 bearing,

or stem adapter with a punch or hammer

Replace the stem adapter O-ring if necessary

Inspect the bearing cap to ensure that an extra race,

held by grease tension is not retained inside

Clean the bearing cap and lubricate the threads

Install the cap using a 24” wrench

Rotate the stem adapter counterclockwise to ensure that the gate is off of the bottom of the body

This will confirm that the stem back seating shoulder is not containing the bonnet shoulder

Inject grease through the bearing cap grease fittings until the excess grease passes through the bleed port

Lubricate the body cavity

GATE AND SEAT REPLACEMENT A

Gate and Seat Disassembly – Manual Valve Refer to Section ‘C’ for gate and seat disassembly for valves with hydraulic actuators

Isolate the valve from the line pressure

Release the cavity pressure

Fully open the valve to ensure that the stem is completely within the gate neck

Remove the bonnet nuts

Turn the hand-wheel clockwise to raise the bonnet from the body

Continue hand-wheel rotation until the face of the bonnet clears the body to provide access to the hole in the top end of the retainer plate

Insert a pin approximately •” in diameter by ¾” long in each of the four holes located near the bonnet face end of the retainer plates

Place two bonnet nuts as spacers on each side of the body cavity between the bonnet and the body faces

Turn the hand-wheel counterclockwise until the retainer plates are pulled out against the bonnet

If the ports of the seat ring are not exposed,

stacking additional nuts as spacers

Support the bonnet and turn the hand-wheel clockwise until the stem completely backs out of the gate

Remove the bonnet assembly

Pull the gate and seat assembly from the body

On ‘FC’ valves only,

remove the body bushings and guides

Use one of the following methods to remove the body bushings if they stick

Insert the screwdriver or pry bar between the groove in the

OD of the bushing and the wall of the body cavity

Pull on the bar,

alternating from side to side of the bushing,

until it loosens enough to remove by hand

Remove the bushing and pry tool

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

Gate and Seat Assembly – Manual Valve Refer to Section ‘D’ for gate and seat assembly for valves with hydraulic actuators

Inspect all gate and seat assembly parts for damage

Ensure that the retainer plates are not bent,

or distorted at the seal ring opening

Solid material should not be built up on the ends

Ensure that the seal rings are not damaged

Ensure that the seat rings do not have cuts or other damages

Ensure that the gate does not have cuts or other damages

Replace any damage parts

Ensure that the body cavity is free of all foreign matter such as solid particles,

Clean the body cavity with a suitable cleaning solvent

Lubricate the body cavity and the gate and seat assembly parts on all sides

On ‘FC’ valves only

Lubricate the body bushing seal rings and body bushings

Install the body bushing,

Ensure that the body bushing seal rings are installed against the valve body

Install the guides into the body cavity

Assemble the gate and seat assembly parts

Slide the gate and seat assembly into the body according to the following guidelines: a

Do not pinch the seat-to-body seals,

or apply heavy impact loads to the parts

Only light impacting on the gate or retainer plate can be tolerated

Most valves require effort,

to force the gate and seat assembly into the cavity

While pushing the gate and seat assembly into the body cavity,

ensure that the top edge of the gate extends slightly farther into the cavity than the top edge of the retainer plates

If a retainer plate leads the gate into the cavity,

pounding the retainer place can break the seat ring

On valves 10,000 PSI WP and above,

must not protrude above the bonnet face

On valves

Acceptable

Unacceptable

the retainer plates may protrude by as much as 1/64”

Do not attempt to drive the retainer plates further into the body once they have reached the bottom

Push the gate all the way to the bottom and hand pack the remaining space with grease

Remove the seal ring from the bonnet groove

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

Apply a very thin film of grease to the seal ring and groove

Install the new seal ring in the bonnet groove

Install the bonnet over the body studs

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

On valves 10,000 PSI WP and above,

rotate the bonnet until the grease fitting is 90• from the gate bore

Turn the hand-wheel counterclockwise to thread the stem into the gate and pull the bonnet down over the studs

Hand-tighten the bonnet nuts

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

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

Gate and Seat Disassembly – Valves with Hydraulic Actuators 1

Bleed off the pressure in the valve body

Apply 250 to 300 PSI (17

3 to 20

Reduce the actuator pressure to zero

Remove the hydraulic lines from the valve

Disassemble the actuator

Remove the hand-wheel from valves with manual locking screws

Remove the set screws from the adjusting nut

Using a pipe wrench,

turn the adjusting nut counterclockwise,

with the locking screw intact,

and remove it from the actuator

Using a box wrench,

remove the nuts from the cylinder head studs

Remove the cylinder head and the studs

Remove the cylinder from the actuator

Caution: Do not damage the inside cylinder surface

If the valve is equipped with a manual locking screw,

unscrew the set screw and remove the centering pin from the gate stem

Remove the lock nut by turning it counterclockwise

i Remove the piston by turning it counterclockwise

Remove the packing gland and stem packing

Remove the bonnet nuts and the bonnet

Push the gate into the body to expose the pulling pin holes in the retainer plates

Insert a pin approximately •”diameter by ¾” long in each of the four holes located near the bonnet face end of the retainer plates

Pull straight up on the gate stem to remove the gate and seat assembly from the valve

On ‘FC’ valves only,

remove the body bushing and guides

Use one of the following methods to remove the body bushings if they st ick

Insert the screwdriver or pry bar between the groove in the OD of the bushing and the wall of the body cavity

Pull on the bar,

alternating from side to side of the bushing,

until it loosens enough to remove by hand

Remove the bushing and pry tool

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

Gate and Seat Assembly – Valves with Hydraulic Actuators 1

Inspect all gate and seat assembly parts for damage

Ensure that the retainer plates are not bent,

or distorted at the seal ring opening

Solid material should not be built up on the ends

Ensure that the seal rings are not damaged

Ensure that the seat rings do not have cuts or other damages

Ensure that the gate does not have cuts or other damages

On ‘FC’ Valves only,

ensure that the body bushing seal rings,

Replace any damaged parts

Install the gate onto the lower stem

Install the replacement gate onto the gate stem by turning the gate counterclockwise until it stops on the stem shoulder

Turn the gate • turn clockwise 3

Ensure that the body cavity is free of all foreign matter such as solid particles,

Clean the body cavity with a suitable cleaning solvent

Lubricate the body cavity and the gate and seat assembly parts on all sides

On ‘FC’ valves only a

Lubricate the body bushing seal rings and body bushings

Install the body bushings,

Ensure that the body bushing seal rings are installed against the valve body

Install the guides into the body cavity

Assemble the gate and seat assembly parts

Slide the gate and seat assembly with the stem attached into the body according to the following guidelines

Do not pinch the seat-to-body seals,

or apply heavy impact loads to the parts

Most valves require effort,

to force the gate and seat assembly into the body cavity,

ensure that the top edge of the gate extends slightly farther into the cavity than the top edge of the retainer plates

If a retainer plate leads the gate into the cavity,

pounding the retainer can break the seat ring

On valves 10,000 PSI WP and above,

must not protrude above the bonnet face

On valve 5000 PSI WP and below,

the retainer plates may protrude by as much 1/64”

Do not attempt to drive the retainer plates further into the body once they have reached bottom

Keep the gate stem from turning,

and tap the gate with a rubber hammer until the lower stem backseats

Remove the seal ring gasket from the bonnet groove

Clean the seal ring grooves and/or seating area of the body and bonnet

Apply a very thin film of grease to the seal ring and groove

Install the new seal ring in the bonnet groove

Install the bonnet over the body studs

On valves 5000 PSI WP and below,

rotate the bonnet so that the bonnet locating pins in the bodies align with the pin holes in the bonnet

On valves 10,000 PSI WP and above,

rotate the bonnet until the grease fitting is 90• from the gate bore

Install the stem packing gland and the stem packing so that the round teflon nose of the packing faces the pressure

Install the bonnet nuts

Assemble the actuator

Keep the gate stem from turning,

and install the piston onto the gate stem by turning clockwise until the piston stops

Continue turning the piston clockwise to pull the gate off the backseat shoulder

If the gate stem position changed during installation: 1) Remove the piston,

and turn the gate stem counterclockwise until it stops on the gate

Keep the piston and gate stem from turning,

and install the lock nut onto the piston hand-tight

Attach the centering pin to the gate stem with the set screw

Install the cylinder studs into the bonnet lower cylinder head,

with one thread of the studs flushed or below the bottom of the cylinder head

Install the O-rings onto the adjusting nut

With the close port up,

slide the cylinder over the piston

Install the upper cylinder head over the studs

Install the nuts onto the cylinder head

Install the adjusting nut and align the gate and seat assembly

Valves with manual locking screws

Do not tighten the set screws at this time

Caution: Do not apply more than 300 PSI (20

Valves without manual locking screws

Do not tighten the set screws at this time

Caution: Don apply more than 300 PSI (20

Reduce the pressure to zero

Turn the adjusting nut ¼ turn counterclockwise

Reapply 300 PSI hydraulic pressure (20

Ensure that the gate bore is aligned with the body bore

If the bore is aligned,

If the bores are not aligned,