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
I. 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. a. Remove the grease fitting cap located on the bonnet flange OD b. Using either a bucket type gun, or hand held type, connect the grease gun coupler to the grease fitting. c. Pump the appropriate amount of lubricant into the body cavity. 2. Unusual Temporary Operating Conditions If it becomes necessary to cement through, acidize through, or subject the valve to any other unusual services: a. Lubricate the valve body cavity before it is put into operation. b. Flush the valve with appropriate neutralizing fluid after it is removed from service. c. Operate the valve with fresh water or appropriate neutralizing fluid in the line. d. Lubricate the valve body cavity. B. Thrust Bearing Lubrication Lubricate the thrust bearings as often as required to ensure smooth valve operation. 1. Using a grease gun, connect the grease gun fitting to the hydraulic grease fitting 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.
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II. TROUBLESHOOTING PROBLEM
CAUSE
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.
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III. BONNET GREASE FITTING REPLACEMENT A. Valve 5000 PSI WP below 1. Backseat the valve a. Close the valve fully. b. Loosen the bearing cap four complete turns using a 24” pipe wrench. c. 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. d. Bump the hand-wheel in the closing directions. 2. Test the effectiveness of the backseat. a. Remove the grease fitting cap. b. Trip the ball in the grease fitting check valve by inserting a •” diameter by ¾” 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, 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 step 1 and 2. 2) If the backseat continues to be ineffective, contact MCM. 3. Remove the grease fitting from the valve bonnet. 4. Install a new grease fitting. B. Valve 10,000 PSI WP and Above NOTE: These valves have a “buried” check valve beneath the bonnet grease fitting. 1. Remove the grease fitting cap. 2. Trip the ball in the grease fitting check valve by inserting •” diameter by ¾” long pin into the run of the fitting. 3. Replace the cap slowly until the ball in the fitting is unseated. 4. If the trapped pressure escapes quickly, then stops, the “buried” check valve is holding pressure. a. Remove the grease fitting b. Install a new grease fitting.
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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) 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. 4) Bump the hand-wheel 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. c. Remove the grease fitting. d. 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 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. 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 bearing and bearing races from the stem adapter. 6. Discard any pitted, cracked, or damaged bearing or races. 7. Discard the stem adapter if either bearing surface on the adapter shoulder is damaged. B. Install the New Thrust Bearings 1. 2. 3. 4. 5.
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.
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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. 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 bearing, races, or stem adapter with a 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 at the bottom of the body. This will confirm that the stem back seating shoulder is not contacting the bonnet shoulder. 13. 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 turns using a 24” pipe wrench. c. 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. d. Bump the hand-wheel in the closing direction. 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 •” diameter by ¾” 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 MCM. b. Valve 10,000 PSI WP and above 5
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 •” diameter by ¾” 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 step 1 and 2. 6) Remove the grease fitting. 7) Remove the protective collar from the check valve unseating tool. 8) Install the unseating tool in the bonnet grease fitting preparation. 9) Slowly turn 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. 11) If no pressure escapes, the “buried” check valve is defective. Proceed to step 14. 12) If pressure continues to escape, the backseat is ineffective. Proceed to step 14. 13) If the backseat continues to be ineffective, contact MCM. 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 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. 6. Remove the adapter from the stem. 7. Remove both sets of bearings and bearing races from the stem adapter. 8. Using a 24” pipe wrench, 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. a. Use Packing sleeve appropriate for your stem, whether 1” or 1-1/4” stem size.
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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 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. B. 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. 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 the stem, the stuffing box bore, and the ID and OD of the stem packing. 5. Install the new packing over the end of the stem so that the rounded Teflon® nose of the packing faces the pressure. 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. 8. Install the packing gland with a 24” pipe wrench. Apply approximately 200 ft-lb of torque, ensuring that the bonnet threads are not damaged. 9. Inspect the bearing and bearing races on the stem adapter for pits, scores, or cracks. Replace if damages. 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 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.
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Caution: Do not strike the bearing, races, or stem adapter with a 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 using a 24” wrench. 20. 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. 21. Inject grease through the bearing cap grease fittings until the excess grease passes through the bleed port. 22. Lubricate the body cavity. VI. 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. 1. Isolate the valve from the line pressure. 2. Release the cavity pressure. 3. Fully open the valve to ensure that the stem is completely within the gate neck. 4. Remove the bonnet nuts. 5. 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. 6. 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. 7. Place two bonnet nuts as spacers on each side of the body cavity between the bonnet and the body faces. 8. Turn the hand-wheel counterclockwise until the retainer plates are pulled out against the bonnet. 9. If the ports of the seat ring are not exposed, repeat step 7, stacking additional nuts as spacers. 10. Support the bonnet and turn the hand-wheel clockwise until the stem completely backs out of the gate. 11. Remove the bonnet assembly. 12. Pull the gate and seat assembly from the body. 13. On ‘FC’ valves only, remove the body bushings and guides. a. Use one of the following methods to remove the body bushings if they stick. 1) Pry out the bushings with a screwdriver or pry bar. a. Insert the screwdriver or pry bar between the groove in the
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OD of the bushing and the wall of the body cavity. b. Pull on the bar, alternating from side to side of the bushing, until it loosens enough to remove by hand. c. Remove the bushing and pry tool. 14. Flush the body cavity thoroughly with a suitable solvent and wipe clean with a rag. B. Gate and Seat Assembly – Manual Valve Refer to Section ‘D’ for gate and seat assembly for valves with hydraulic actuators. 1. Inspect all gate and seat assembly parts for damage. a. Ensure that the retainer plates are not bent, twisted, or distorted at the seal ring opening. Solid material should not be built up on the ends. b. Ensure that the seal rings are not damaged. c. Ensure that the seat rings do not have cuts or other damages. d. Ensure that the gate does not have cuts or other damages. 2. Replace any damage parts. 3. Ensure that the body cavity is free of all foreign matter such as solid particles, grit, trash, dirt, etc. 4. Clean the body cavity with a suitable cleaning solvent. 5. Lubricate the body cavity and the gate and seat assembly parts on all sides. 6. On ‘FC’ valves only. a. Lubricate the body bushing seal rings and body bushings. b. Install the body bushing, with seal rings, into the body cavity. c. Ensure that the body bushing seal rings are installed against the valve body. d. Install the guides into the body cavity. 7. Assemble the gate and seat assembly parts. 8. 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. b. Most valves require effort, gently applied, 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. c. On valves 10,000 PSI WP and above, the retainer plates, when
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installed, must not protrude above the bonnet face. On valves
Acceptable
Unacceptable
5000 PSI WP and below, 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. 9. Push the gate all the way to the bottom and hand pack the remaining space with grease. 10. Remove the seal ring from the bonnet groove. 11. Clean the grooves and/or seating area of the body and bonnet. 12. Apply a very thin film of grease to the seal ring and groove. 13. Install the new seal ring in the bonnet groove. 14. 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. b. On valves 10,000 PSI WP and above, rotate the bonnet until the grease fitting is 90• from the gate bore. 15. Turn the hand-wheel counterclockwise to thread the stem into the gate and pull the bonnet down over the studs. 16. Hand-tighten the bonnet nuts. 17. Ensure that the gate is not on the bottom of the cavity. 18. 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. C. Gate and Seat Disassembly – Valves with Hydraulic Actuators 1. Bleed off the pressure in the valve body. 2. Apply 250 to 300 PSI (17.3 to 20.7 Bars) actuator pressure to the OPEN port, opening the valve. 3. Reduce the actuator pressure to zero.
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4. Remove the hydraulic lines from the valve. 5. Disassemble the actuator. a. Remove the hand-wheel from valves with manual locking screws. b. Remove the set screws from the adjusting nut. c. Using a pipe wrench, turn the adjusting nut counterclockwise, with the locking screw intact, and remove it from the actuator. d. Using a box wrench, remove the nuts from the cylinder head studs. e. Remove the cylinder head and the studs. f. Remove the cylinder from the actuator. Caution: Do not damage the inside cylinder surface. g. If the valve is equipped with a manual locking screw, unscrew the set screw and remove the centering pin from the gate stem. h. Remove the lock nut by turning it counterclockwise. i Remove the piston by turning it counterclockwise. j. Remove the packing gland and stem packing. 6. Remove the bonnet nuts and the bonnet. 7. Push the gate into the body to expose the pulling pin holes in the retainer plates. 8. Insert a pin approximately •”diameter by ¾” long in each of the four holes located near the bonnet face end of the retainer plates. 9. Pull straight up on the gate stem to remove the gate and seat assembly from the valve. 10. On ‘FC’ valves only, remove the body bushing and guides. a. Use one of the following methods to remove the body bushings if they st ick. 1) Pry out the bushings with a screwdriver. a. Insert the screwdriver or pry bar between the groove in the OD of the bushing and the wall of the body cavity. b. Pull on the bar, alternating from side to side of the bushing, until it loosens enough to remove by hand. c. Remove the bushing and pry tool. 11. Flush the body cavity thoroughly with a suitable solvent and wipe clean with a rag. D. Gate and Seat Assembly – Valves with Hydraulic Actuators 1. Inspect all gate and seat assembly parts for damage. a. Ensure that the retainer plates are not bent, twisted, or distorted at the seal ring opening. Solid material should not be built up on the ends. b. Ensure that the seal rings are not damaged. c. Ensure that the seat rings do not have cuts or other damages. d. Ensure that the gate does not have cuts or other damages. e. On ‘FC’ Valves only, ensure that the body bushing seal rings, the body bushings, and guides are not damaged.
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2. Replace any damaged parts. a. Install the gate onto the lower stem. 1) Align the hole in the lower gate neck with the hole in the lower ste m. 2) Insert the pin into the hole to hold the stem in place. b. Install the replacement gate onto the gate stem by turning the gate counterclockwise until it stops on the stem shoulder. c. Turn the gate • turn clockwise 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. Lubricate the body cavity and the gate and seat assembly parts on all sides. 6. On ‘FC’ valves only a. Lubricate the body bushing seal rings and body bushings. b. Install the body bushings, with seal rings, into the body cavity. c. Ensure that the body bushing seal rings are installed against the valve body. d. Install the guides into the body cavity. 7. Assemble the gate and seat assembly parts. 8. Slide the gate and seat assembly with the stem attached 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. b. Most valves require effort, gently applied, 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. c. On valves 10,000 PSI WP and above, the retainer plates, when installed, 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. 9. Keep the gate stem from turning, and tap the gate with a rubber hammer until the lower stem backseats. 10. Remove the seal ring gasket from the bonnet groove. 11. Clean the seal ring grooves and/or seating area of the body and bonnet. 12. Apply a very thin film of grease to the seal ring and groove. 13. Install the new seal ring in the bonnet groove. 14. 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 bodies align with the pin holes 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.
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15. Install the stem packing gland and the stem packing so that the round teflon nose of the packing faces the pressure. 16. Install the bonnet nuts. 17. Assemble the actuator. a. Keep the gate stem from turning, and install the piston onto the gate stem by turning clockwise until the piston stops. b. Continue turning the piston clockwise to pull the gate off the backseat shoulder. c. If the gate stem position changed during installation: 1) Remove the piston, and turn the gate stem counterclockwise until it stops on the gate. 2) Turn the gate stem clockwise • turn. 3) Repeat steps 17 a and b. d. Keep the piston and gate stem from turning, and install the lock nut onto the piston hand-tight. e. Attach the centering pin to the gate stem with the set screw. f. 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. g. Install the O-rings onto the adjusting nut. h. With the close port up, slide the cylinder over the piston. i. Install the upper cylinder head over the studs. j. Install the nuts onto the cylinder head. 18. Install the adjusting nut and align the gate and seat assembly. a. Valves with manual locking screws. 1) Install the adjusting nut into the cylinder head by rotating it two turns clockwise. 2) Install the adjusting nut set screws. Do not tighten the set screws at this time. 3) Turn the locking screw ¼ turn counterclockwise to ensure it is backed off. 4) Connect hydraulic lines to the actuator. 5) Apply 300 PSI hydraulic pressure (20.7) to the open port until the piston moves out and stops. Caution: Do not apply more than 300 PSI (20.7 Bars) 6) Maintain the pressure and turn the locking screw clockwise into the cylinder head until it contacts the piston. 7) Reduce the pressure to zero 8) Continue to turn the locking screw clockwise until the gate bore is aligned with the body bore. 9) Turn the screw ¼ turn counterclockwise until it contacts the piston. 10) Turn the adjusting nut clockwise until it contacts the piston. 11) Tighten the set screws to lock the adjusting nut in place.
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b. Valves without manual locking screws. 1) Install the adjusting nut into the cylinder head by rotating it clockwise until it stops. 2) Install the adjusting nut set screws. Do not tighten the set screws at this time. 3) Connect hydraulic lines to the actuator. 4) Apply 300 PSI hydraulic pressure (20.7 Bars) to the open port until the piston moves out and stops. Caution: Don apply more than 300 PSI (20.7 Bars) 5) Ensure that the gate bore is aligned with the body bore. 6) If the bores are aligned, proceed to step 8. 7) If the bores are not aligned: a. Reduce the pressure to zero. b. Turn the adjusting nut ¼ turn counterclockwise. c. Reapply 300 PSI hydraulic pressure (20.7 Bars) to the open port. d. Ensure that the gate bore is aligned with the body bore. e. If the bore is aligned, proceed to step 8. f. If the bores are not aligned, repeat steps 7a through d. 8) Tighten the set screws to lock the adjusting nut in place.
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