GROVE API 6D Fabricated Gate Valve IOM

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Installation, Operation and Maintenance Manual IOM-GRO-GATE-FABRICATED-G7
Installation, Operation and Maintenance Manual
GROVE® API 6D
FABRICATED GATE VALVES
Installation, Operation and Maintenance Manual IOM-GRO-GATE-FABRICATED-G7
TABLE OF CONTENTS
GROVE® API 6D
FABRICATED GATE VALVES
16” – 42” CLASS 150-600 MODEL “G7” .................................................................................... 1
SCOPE ...................................................................................................................................... 2
NAMEPLATE INFORMATION ................................................................................................... 2
SAFETY INFORMATION ........................................................................................................... 3
STORAGE ................................................................................................................................. 3
INSTALLATION ......................................................................................................................... 4
HYDROSTATIC TESTING ......................................................................................................... 6
OPERATION .............................................................................................................................. 7
ROUTINE MAINTENANCE ........................................................................................................ 9
DRAINING AND FLUSHING VALVE .........................................................................................10
LOW TEMPERATURE PRECAUTIONS ...................................................................................12
LUBRICATING HANDWHEEL AND OPERATOR ASSEMBLY .................................................14
LUBRICATING SEATS .............................................................................................................15
RECOMMENDED LUBRICANTS AND SEALANTS ..................................................................15
TROUBLESHOOTING ..............................................................................................................17
APPENDIX ................................................................................................................................19
Installation, Operation and Maintenance Manual 1 IOM-GRO-GATE-FABRICATED-G7
16” – 42” CLASS 150-600 MODEL “G7”
ITEM
DESCRIPTION
1.
BODY
2A.
SEAT LUBE FITTING
2B.
STEM BACKSEAT FITTING
3A.
DRAIN FITTING
3B.
VENT FITTING
*
4.
SEAT ASSEMBLY
*
5.
GREASE O-RING
*
6.
SEAT O-RING
*
7.
WAVE SPRING
*
8.
GATE
*
9.
STEM ASSEMBLY
9A.
STEM
9B.
STEM HEAD
9C.
STEM PIN
*
10.
BONNET SEAL
11.
BONNET
12.
BONNET STUD
13.
BONNET NUT
*
14.
PEDESTAL
*
15.
SLS SEAL
16.
LANTERN RING
*
17.
PRESSURE RING
18.
UPPER ADAPTER RING
19.
PACKING FITTING
ASSEMBLY
20.
PACKING PLUG
21.
YOKE TUBE
22.
STUD
23.
DRAIN PLUG
*
24.
GASKET
105.
BOLT
109.
INDICATOR ROD
*
110.
ROD WIPER
111.
STEM PROTECTOR
112.
STOP RING NUT
113.
SET SCREW
114.
BEVEL GEAR OPERATOR
WITH HANDWHEEL
115.
PLASTIC PLUG
*RECOMMENDED SPARE PARTS
Installation, Operation and Maintenance Manual 2 IOM-GRO-GATE-FABRICATED-G7
Figure 2 – Grove Fabricated Gate Valve
Nameplate
SCOPE
This manual covers the Grove Model “G7”
Fabricated Gate Valve product line. Drawings
shown are typical. The design of specific valves
may vary slightly from the drawings.
The Grove “G7” Fabricated Gate Valve is a
through-conduit slab gate valve. It utilizes two
floating seats to provide a complete seal with the
gate. The full bore design has the same
pressure drop as an equivalent length of pipe
and allows passage of all types of scrapers
(pigs). The valve stroke is established by a stop
ring located on the stem and the stem backseat.
The backseat is an added safety feature which
allows for a seal between the stem and bonnet
when in the open position. It also provides a
means of stem retention in the body. The valve
can be repaired while in line (pressure removed
and valve drained).
The stem is sealed by spring-loaded lip seals. In
an emergency, plastic packing can be injected
into the packing box to affect a temporary seal
while the valve is under pressure.
The valve does not depend on lubricant for a
seal in normal operation. However,
lubricants/sealants can be injected to promote
smooth operation. Seat sealant can also be
injected to affect a seal in an emergency should
the seats become damaged by foreign matter.
Excess body pressure is automatically vented to
the upstream conduit by the self relieving seat.
External body cavity relief systems are not
required.
Grove “G7” Fabricated Gate Valves are
available in sizes, pressure classes, materials,
and coatings to meet industry requirements.
Valves are available with
lubrication/packing/drain extensions and
stem/yoke tube extensions.
NAMEPLATE INFORMATION
ITEM
STAMP
1.
Nominal Valve Size
2.
Maximum Cold Working Pressure (psig)
3.
*Serial Number
4.
API Class Designation
5.
Minimum Temperature in °F
6.
Maximum Temperature in °F
7.
*Bill of Material Number
8.
Body Material Designation
9.
End Material Designation
10.
Gate Material Designation
11.
Seat Material Designation
12.
Stem Material Designation
13.
Seal Material Designation
14.
(Maximum Operating Pressure at 250°F – if Applicable)
15.
(API Monogram - if Applicable)
16.
Model Designation
17.
(Marking for Non-Standard End-to-End - if Applicable)
18.
Date of Manufacture
19.
(Impact Test Temperature - if Applicable)
( )
Description in parenthesis may be left blank in some
cases.
*
Most important data for obtaining replacement parts.
Nameplate may vary.
16
4
3
5
18
19
15
6
13
1
14
7
2
8
9
10
11
12
17
Installation, Operation and Maintenance Manual 3 IOM-GRO-GATE-FABRICATED-G7
SAFETY INFORMATION
Valves shall be operated and maintained
strictly in accordance with these procedures.
Operation or maintenance outside these
procedures constitutes abuse of the product
and voids all warranty and claims.
When special operation is required, a formal
written request to the company must be
made for approval to operate in this manner
if warranty and product liability is to be
maintained.
The personnel working on the installation shall
always use safety precautions set forth by the
law and any regulations required by the
employer. The maintenance personnel doing the
repairs should be well trained and familiar with
all the information contained in this manual.
The valves shall be appropriately used for the
purpose they are built for. Transport, unpacking,
lifting, and connections to the different types of
systems (electric, pneumatic, hydraulic systems,
etc.) shall be made by expert and qualified
personnel.
Do not carry out any actions when the results
are uncertain. This includes lifting, repairing, or
removing and reapplying pressure.
Do not remove or tamper with protections or
safety devices of any types.
Do not use the valve before the efficiency of all
safety devices has been restored.
STORAGE
After Grove “G7” Fabricated Gate Valves are
assembled and tested, the valves are left in the
open position, seats and bores are greased and
end protectors are installed. These measures
will provide protection for approximately six
months. The following care should be taken
when storing valves:
1. Make sure the valve end connection covers
remain in place during storage.
2. If the valve does not have an operator and the
valve will be stored outside, the exposed stem or
the stem adapter should be covered to avoid
accumulation of water and debris.
If long-term storage is required, the valve should
be conditioned by following Cameron procedure
X-150771-01.
Ensure adequate end connection covers are in
place. Request a copy of X-150771-01 from the
Cameron Valves & Measurement group.
Installation, Operation and Maintenance Manual 4 IOM-GRO-GATE-FABRICATED-G7
INSTALLATION
Grove “G7” Fabricated Gate Valves are bi-
directional and have no preferred pressure end.
Overhaul and repair is easier with the valve in
the "stem vertical" position. Before handling the
valve, clearly identify and record the nameplate
information. Check its weight with the packing
list or relevant documents and use suitable
handling equipment. When handling or installing
the valve, keep the valve in the open position
whenever possible to prevent foreign matter
damage to the gate and seat sealing surfaces.
The valve should be lifted in such a way that the
body supports the load. This can be done via
lifting holes on the body ribs as illustrated in
Figure 3. Special rigging will be necessary with
installed automated system.
CAUTION: Do not use handwheels or other
protruding parts of the valve, gearbox, or
actuator to lift the valve. During handling,
use care to avoid damaging the end
connection faces, fittings, and accessories.
The end connection necks on the valve body
are suitable places to attach lifting slings, if
lifting holes are not an option.
Flange End Valves may be bolted into line
using two open boxed end wrenches. Power
wrenches may be required for larger valves.
1. Use solvent to clean grease or rust inhibitor
from the gate and/or bore of the valve.
2. Make sure the line flanges are properly
aligned and will not distort or bind the valve. Use
new flange gaskets.
3. Bolt and nut threads should be lubricated to
obtain proper loading of bolt, as well as the
bearing surface of the nut.
4. Finger-tighten all nuts first.
5. Tighten bolts, using the crisscross method,
and torque each bolt to ASME or gasket
manufacturer’s specification.
Butt Weld End Valves should be welded into
the line by qualified welders, using qualified
procedures. Cameron's Valves & Measurement
group recommends that all welding procedures
and welders be qualified per ASME Section IX.
CAUTION: Keep weld end valves open while
installing/welding into the line. Weld slag
created during the welding process could
damage gate sealing surfaces.
1. Use solvent to clean grease or rust inhibitor
from the gate and/or bore of the valve.
2. Make sure the line and valve weld bevels are
properly aligned and will not bind the valve.
3. Electric welding equipment is preferred for all
installations. However, if only oxygen-acetylene
welding equipment is available, extreme caution
should be taken regarding excess welding
temperature to prevent damage to sealing
components of the valve.
4. Weld with the gate in "Full Open" position.
5. Make sure temperature of the body/seat area
does not exceed 250°F. (Check with Tempil®
stick or equivalent).
6. Avoid rapid application of excess welding
material. Weld each end of the valve with a
continuous bead using a 1/8" maximum
diameter electric welding rod.
7. Keep the valve in the "Full Open" position
until the line has been thoroughly cleaned of
weld slag in the valve bore and line (by pigging
and/or flushing) before changing the position of
the gate.
Installation, Operation and Maintenance Manual 5 IOM-GRO-GATE-FABRICATED-G7
Figure 3 – Various Lifting Techniques
Installation, Operation and Maintenance Manual 6 IOM-GRO-GATE-FABRICATED-G7
Figure 4 – Test Pressures per ASME B16.34
HYDROSTATIC TESTING
When Grove “G7” Fabricated Gate Valves are
installed in a piping system that requires
hydrostatic testing of the adjoining pipe, follow
these procedures to minimize any damage that
could occur to the sealing surface and seat
seals inside the valve.
CAUTION: Ensure that all test fluids contain
corrosion inhibitors and that they are
compatible with the valve seat and seal
materials.
1. The valve should be in the fully open position
when the injection of test fluids begins. This will
allow any pipeline debris to be flushed through
the valve bore and out of the piping.
2. Once the piping system has been purged of
debris and the system has been filled completely
with the test fluid, the gate should be placed in
the partially open position to allow test fluid into
the body cavity of the valve.
3. The valve is now ready to be hydrostatically
pressure tested.
CAUTION: Do not exceed pressures listed on
the table below. The Maximum Allowable
Working Pressure (MAOP) is marked on the
nameplate.
4. Upon completion of hydrostatic testing, the
valve should be returned to the fully open
position before removing the test fluid from the
piping system. The test fluid in the body cavity
can be drained through the body drain port
located in the lower portion of the valve. (See
Draining Valve, Page 10).
5. Once the valve body has been completely
drained, close the body bleed fitting. (See
Draining Valve, Page 10). After securing the
safety cap back on the drain fitting, return the
valve to required operating position, either fully
open or fully closed.
6. The valve seat pockets should be filled with
an approved valve lubricant to displace any test
fluid from behind the seats.
Pressure Class
Hydrostatic Shell
Hydrostatic Seat
psig
(barg)
psig
(barg)
150
450
(31)
325
(23)
300
1125
(78)
825
(57)
600
2225
(154)
1650
(114)
900
3350
(231)
2450
(169)
Installation, Operation and Maintenance Manual 7 IOM-GRO-GATE-FABRICATED-G7
OPERATION
The Grove “G7” Fabricated Gate Valve may be
operated with a handwheel or may be power
actuated. With either mode of actuation, open
and close the valve completely. DO NOT
THROTTLE FLOW.
The valve, in good condition, will seal at low
pressures up to the maximum allowable working
pressures as a block valve, single-block-and-
bleed valve or a double-block-and-bleed valve.
Valves equipped with handwheels are CLOSED
by turning the handwheel CLOCKWISE until a
stop is felt. The indicator rod at the top of the
valve will move down (towards the valve bore),
as the handwheel is turned CLOCKWISE.
The valve is OPENED by turning the handwheel
COUNTER-CLOCKWISE until it contacts the
stop. The indicator rod at the top of the valve will
move up (away from the valve bore), as the
handwheel is turned COUNTER-CLOCKWISE.
When valves are equipped with power actuators,
the movement of the indicator rod will indicate if
the valve is being opened or closed. Make sure
all accessories recommended by the actuator
manufacturer are installed before valve actuator
installation. Should any maintenance be
necessary, obtain the part number from the
unit's nameplate and contact Cameron's Valves
& Measurement group or the nearest service
representative.
Actuator Mounting
Actuators should only be installed by trained and
experienced personnel. Follow the actuator
manufacturer's instructions for installation on the
valve and making of electrical connections. The
following outlines basic procedures when not
provided by the actuator manufacturer:
Side Mounted Actuator on a Bevel Gear
Operator (BGO)
1. Suspend the BGO above the valve with a
strap or chain in such a way that the base of the
BGO is parallel with the mounting plate on the
valve yoke.
2. Slowly lower the BGO onto the valve stem
until the top of the valve stem makes contact
with the bottom of the stem bushing.
3. Carefully rotate the BGO until the threads
engage.
4. Slowly lower and rotate (counter-clockwise for
Left Hand thread, clockwise for Right Hand
thread) the BGO onto the valve stem until the
base of the BGO rests on the mounting plate.
5. If the orientation of the BGO is incorrect at
this point it is possible to rotate the BGO into the
correct position by turning the hand-wheel/pinion
shaft until the proper orientation is achieved.
6. Install and tighten the BGO mounting bolts.
7. Suspend the actuator so that the output shaft
is in-line and parallel to the bevel gear operator
pinion shaft.
8. Install the coupling, key or other means to
connect the two shafts.
9. Slide the actuator onto the BGO and install
the bolts.
10. Ensure that the valve is not seated in the
down or closed position prior to installing and
tightening actuator mounting bolts.
11. Tighten bolts securely following the actuator
manufacturer’s instructions.
Direct Mounted Actuator with a Removable
Thrust Base
For non-removable stem nut or bushing:
1. Remove the thrust base from the actuator.
Refer to the manufacturer’s instructions or
drawings for guidance.
2. Suspend the THRUST BASE above the valve
with a strap or chain in such a way that the base
of the THRUST BASE is parallel with the
mounting plate on the valve yoke.
3. Slowly lower the THRUST BASE onto the
valve stem until the top of the valve stem makes
contact with the bottom of the stem bushing.
Installation, Operation and Maintenance Manual 8 IOM-GRO-GATE-FABRICATED-G7
4. Carefully rotate the THRUST BASE until the
threads engage.
5. Slowly lower and rotate (counter-clockwise for
LH thread, clockwise for RH thread) the
THRUST BASE onto the valve stem until the
base of the THRUST BASE rests on the
mounting plate.
6. Install and tighten the mounting bolts that
attach the Thrust Base to the valve.
7. Reinstall the actuator on the Thrust Base
verifying that the proper orientation is achieved
and tighten the mounting bolts that attach the
actuator to the Thrust Base.
For removable stem nut or bushing:
1. Remove the stem nut from the actuator.
2. Suspend the actuator above the valve with a
strap or chain in such a way that the base of the
actuator is parallel with the mounting plate on
the valve yoke.
3. Slowly lower the actuator over the valve stem
until the base of the actuator rests on the
mounting plate.
4. Verify that the proper orientation is achieved.
5. Ensure that the valve is not seated in the
down or closed position prior to installing and
tightening actuator mounting bolts6.
6. Install and tighten the actuator mounting bolts.
7. Carefully thread the stem nut onto the valve
stem and rotate the nut until it is engaged with
the drive sleeve.
8. Rotate the actuator hand-wheel in the open
direction until the stem nut is fully engaged in
the drive sleeve.
9. Install and tighten the stem nut locking nut.
10. Use a center punch to stake the threads of
the stem nut locking nut to the actuator drive
sleeve.
Procedure for Setting Down Stop
Install the stem thread stop nut as follows for
gear boxes/operators with no limit switches:
Normal Acting gate (most common)
1. Move the valve to the OPEN position (stem
up).
2. Thread the stop nut onto the stem until the
distance between the bottom of the stop nut and
the top of the stem nut in the actuator is equal to
the total stem travel. The valve Operator
Interface drawing (sometimes called a “Top
Works” drawing), shows the stem travel from the
OPEN to the CLOSED position.
3. Install the set screws and tighten securely.
Reverse Gate (unusual)
1. Move the valve to the OPEN position (stem
down).
2. Thread the stop nut onto the stem and thread
down until it contacts the stem nut in the
actuator. The valve Operator Interface drawing,
sometimes called a “Top Works” drawing, shows
the stem travel from the OPEN to the CLOSED
position. Use this to set the proper opening
limits.
3. Inspect the bore to ensure proper gate to seat
bore alignment. Install the set screws and
tighten securely.
Procedure for Setting Limit Switches
Unless otherwise specified, set the electric
actuator switches as follows:
Normal Acting gate (most common)
1. OPEN POSITION- Move the valve to the
OPEN (stem up) position. Back off one-quarter
stem turn. Follow the actuator manufacturer's
instructions for setting the limit switch. The limit
should be set so that the stem backseat does
not engage the bonnet landing.
2. If the actuator has a torque switch, set it at no
more than the Block and Bleed Torque value
from the table. However, the limit switch must
stop the valve at the top of the stroke. Do not
use the torque switch to stop the valve in the
open position. Do not let the actuator stall out on
the up or back seated position.
3. CLOSED POSITION-Follow the actuator
manufacturer's instructions for setting the limit
switch so that the actuator stops as the valve
reaches the CLOSED (stem down) position. The
valve Operator Interface drawing (sometimes
Installation, Operation and Maintenance Manual 9 IOM-GRO-GATE-FABRICATED-G7
called a “Top Works” drawing), shows the stem
travel from the OPEN to the CLOSED position.
Use this to set the proper closing limits.
4. Keeping the gate in the CLOSED position,
thread the stop nut onto the stem and thread
down until it contacts the stem nut in the
actuator. Back off the stop nut one-quarter (1/4)
turn. Install the set screws and tighten securely.
Reverse gate (rare)
1. OPEN POSITION- Follow the actuator
manufacturer's instructions for setting the
limit switch so that the actuator stops as the
valve reaches the OPEN (stem down)
position.
2. The valve Operator Interface drawing
(sometimes called a “Top Works” drawing),
shows the stem travel from the OPEN to the
CLOSED position. Use this to set the proper
opening limits. Inspect the bore to
insure proper gate to seat bore alignment.
3. Thread the stop nut onto the stem
and thread down until it contacts the stem
nut in the actuator. Back off the stop nut
one-quarter (1/4) turn. Install the set
screws and tighten securely.
4. If the actuator has a torque switch, set it at
no more than the Block and Bleed Torque
value from the table. However, the limit
switch must stop the valve at the bottom of
the stroke. Do not use the torque switch to stop
the valve in the open position.
5. CLOSED POSITION- Move the valve to the
CLOSED (stem up) position. Back off one-
quarter (1/4) stem turn. Follow the actuator
manufacturer's instructions for setting the limit
switch. The limit should be set so that the stem
backseat does not engage the bonnet landing.
6. The valve Operator Interface drawing
(sometimes called a “Top Works” drawing),
shows the stem travel from the OPEN to the
CLOSED position. Use this to set the
proper closing limits. Do not let the actuator stall
out on the up or back seated position.
Verify that the maximum allowable torque switch
setting of the actuator is not exceeded. This
setting may be indicated by the use of a torque
limiter plate on the torque switch. If no limiter
plate is installed on the torque switch then the
maximum torque value will need to be
determined from supporting documentation that
came with the actuator, nameplate information,
or by contacting the actuator manufacturer.
WARNING: Exceeding a limiter plate setting
can result in reaching or exceeding stall
torque of the actuator motor or maximum
allowable torque for actuator. This can result
in equipment damage and personnel injury.
At no time should a limiter plate be removed
without written approval from the actuator
manufacturer.
ROUTINE MAINTENANCE
The following outlines the minimum scheduled
maintenance required for Grove “G7” Fabricated
Gate Valves to promote trouble-free service and
long life. Some applications may require more
maintenance. Visually inspect every six (6)
months.
See troubleshooting section (Page 17) for a list
of remedies to troubles that may arise. If
remedies are not sufficient, contact local
Cameron Valves & Measurement service
representative.
Operate the valve once a month, if practical. A
full open closed cycle is preferable. Operate a
partial cycle as a minimum.
CAUTION: Verify compatibility of any
sealant, lubricant, or anti-freeze with the trim
of the valve and product in the line.
Installation, Operation and Maintenance Manual 10 IOM-GRO-GATE-FABRICATED-G7
DRAINING AND FLUSHING VALVE
After lengthy service, there is a possibility of
water, line scale, sediment or other foreign
matter collecting in the lower body cavity. It is
advisable to periodically drain the valve to
discourage development of conditions that can
possibly lead to valve damage or impair the
operation of the valve. If draining is not regularly
scheduled, it is strongly recommended to drain
the valve at these times:
1. After hydrostatic testing.
2. After cleaning the line.
3. When valve cannot be fully opened or closed.
(Foreign matter in the bottom of valve can not
only prevent placing valve in a fully closed
position, it can also cause permanent damage to
the internal sealing surfaces).
CAUTION: A safety pressure releasing tool is
required to simplify the procedure of
releasing body pressure or draining the
valve. To release body pressure or to drain
valve, first place the valve in the closed
position.
WARNING: To avoid injury by liquid or
foreign solid matter, individuals should be
safely positioned away from the direction of
the outlet port of the grease fitting. (If the ball
check is not holding pressure, pressure will
blow through the safety holes in the cap.)
Back-up the seat grease fitting using a
wrench so only the safety cap will be
removed from the fitting. Carefully remove
the safety cap from the seat grease fitting.
NEVER remove the grease fitting with the
valve under pressure!
1. Carefully remove the vented safety cap of the
lower drain grease fitting, Figure 5. Contact your
local Cameron Valves & Measurement service
representative for further assistance, if needed.
2. Back out the stinger of the pressure releasing
tool until it stops.
3. Install the pressure releasing tool onto the
uncapped grease fitting. The ball check on the
grease fitting should still be closed, Figure 6.
4. Carefully screw the stinger of the releasing
tool- (until the ball check in the grease fitting is
pushed off its seat, Figure 7). This will allow the
valve to drain or to release body pressure.
5. After completion, back out the stinger of the
pressure releasing tool to allow the ball check in
the grease fitting to reseat and permit easy
removal of the pressure releasing tool.
6. Replace safety cap on the lower drain grease
fitting.
For flushing of body, install a valve on the drain.
Use internal procedures to flush water, anti-
freeze, etc. from the body.
WARNING: Do not replace yoke tube plastic
plug with a metal plug/fitting. There is a risk
of pressure becoming trapped in the yoke
tube which could cause injury.
Installation, Operation and Maintenance Manual 11 IOM-GRO-GATE-FABRICATED-G7
Figure 6 – Pressure Releasing Tool
as Installed (Ball Check Closed).
Figure 5 - Grease Fitting
STINGER
GREASE FITTING
Figure 7 - Pressure Releasing Tool with Stinger
Screwed In (Ball Check Open and Venting).
Part Number K021960 for ½” fittings.
Part Number K032287 for 1” fittings.
Installation, Operation and Maintenance Manual 12 IOM-GRO-GATE-FABRICATED-G7
LOW TEMPERATURE PRECAUTIONS
Prior to exposure to freezing temperatures it is
highly recommended the valve be drained.
Water that may be trapped in the body cavity
could freeze and impair the operation of the
valve or damage the valve.
If the valve has a grease fitting in the lower
drain, a sufficient amount of anti-freeze injected
into the body cavity via the lower drain grease
fitting will prevent accumulated water from
freezing. It is also advisable to inject a sufficient
amount of valve lubricant into the grease fittings
of the valve and operator (if present) prior to
extended cold temperature exposure.
Trapped water should be drained from stem
extensions. Some stem extensions in the field
are equipped with plastic plugs that can be
removed to drain trapped water from the piped
extension.
Volume of Anti-freeze (Ethylene Glycol) to Prevent Freezing (Gallons)
Minimum
Expected
Temperature
18°F
(-8°C)
13°F
(-11°C)
7°F
(-14°C)
-8°F
(-22°C)
-28°F
(-33°C)
-55°F
(-48.5°C)
Body
Volume
in the
Open
Position
Body
Volume
in the
Closed
Position
Percent
Anti-Freeze
18%
23%
28%
37%
48%
59%
16”
150
2.0
2.5
3.0
4.0
5.0
6.5
8.8
10.4
16”
300
2.0
2.5
3.0
4.0
5.5
6.5
8.9
10.5
16”
600
2.5
3.0
3.5
5.0
6.0
7.5
10.3
12.3
18”
150
2.5
3.5
4.0
5.5
7.0
8.5
11.6
13.7
18”
300
2.5
3.5
4.0
5.5
7.0
8.5
11.7
13.7
18”
600
3.5
4.5
5.0
7.0
9.0
11.0
14.8
17.8
20”
150
3.5
4.5
5.5
7.0
9.0
11.0
15.6
18.2
20”
300
4.0
5.0
6.0
8.0
10.0
12.5
17.5
20.6
20”
600
5.0
6.0
7.5
9.5
12.5
15.0
21.0
25.1
24”
150
5.0
6.0
7.5
10.0
12.5
15.5
22.0
25.9
24”
300
5.5
7.0
8.5
11.0
14.5
17.5
24.8
29.6
24”
600
7.0
9.0
11.0
14.5
18.5
23.0
31.3
38.2
30”
150
8.0
10.5
12.5
16.5
21.0
26.0
37.6
43.7
30”
300
11.0
13.5
16.5
22.0
28.5
34.5
48.7
58.5
30”
600
13.5
17.0
20.5
27.5
35.5
43.5
59.7
73.1
Installation, Operation and Maintenance Manual 13 IOM-GRO-GATE-FABRICATED-G7
LOW TEMPERATURE PRECAUTIONS Continued
Volume of Anti-freeze (Ethylene Glycol) to Prevent Freezing (Gallons)
Minimum
Expected
Temperature
18°F
(-8°C)
13°F
(-11°C)
7°F
(-14°C)
-8°F
(-22°C)
-28°F
(-33°C)
-55°F
(-48.5°C)
Body
Volume
in the
Open
Position
Body
Volume
in the
Closed
Position
Percent
Anti-Freeze
18%
23%
28%
37%
48%
59%
36”
150
13.0
16.5
20.0
26.5
34.5
42.5
60.8
71.4
36”
300
17.5
22.0
27.0
35.5
46.0
56.5
78.4
95.1
36”
600
22.0
28.0
34.0
45.0
58.5
72.0
98.5
121.3
42”
150
17.0
21.5
26.0
34.5
44.5
55.0
70.3
92.4
42”
300
22.5
29.0
35.0
46.5
60.0
73.5
94.2
124.3
42”
600
28.5
36.5
44.0
58.0
75.5
92.5
118.5
156.6
Volume of Anti-freeze (Ethylene Glycol) to Prevent Freezing (Liters)
Minimum
Expected
Temperature
18°F
(-8°C)
13°F
(-11°C)
7°F
(-14°C)
-8°F
(-22°C)
-28°F
(-33°C)
-55°F
(-48.5°C)
Body
Volume
in the
Open
Position
Body
Volume
in the
Closed
Position
Percent
Anti-Freeze
18%
23%
28%
37%
48%
59%
16”
150
8
10
12
15
19
24
33.4
39.4
16”
300
8
10
12
15
20
24
33.9
39.9
16”
600
9
11
14
18
23
28
39.1
46.7
18”
150
10
12
15
20
25
31
44.1
51.8
18”
300
10
12
15
20
25
31
44.2
51.9
18”
600
13
16
19
25
33
40
56.2
67.4
20”
150
13
16
20
26
34
41
59.2
68.8
20”
300
15
18
22
29
38
47
66.3
78.1
20”
600
18
22
27
36
46
56
79.5
94.9
24”
150
18
23
28
37
48
58
83.2
98.1
24”
300
21
26
32
42
54
67
93.7
112.2
24”
600
27
34
41
54
70
86
118.7
144.7
Installation, Operation and Maintenance Manual 14 IOM-GRO-GATE-FABRICATED-G7
LOW TEMPERATURE PRECAUTIONS Continued
Volume of Anti-freeze (Ethylene Glycol) to Prevent Freezing (Liters)
Minimum
Expected
Temperature
18°F
(-8°C)
13°F
(-11°C)
7°F
(-14°C)
-8°F
(-22°C)
-28°F
(-33°C)
-55°F
(-48.5°C)
Body
Volume
in the
Open
Position
Body
Volume
in the
Closed
Position
Percent
Anti-Freeze
18%
23%
28%
37%
48%
59%
30”
150
30
39
47
62
80
98
142.5
165.6
30”
300
40
51
62
82
107
131
184.5
221.3
30”
600
50
64
78
103
133
164
226.1
276.7
36”
150
49
63
76
100
130
160
230.0
270.2
36”
300
65
83
101
134
173
213
296.6
360.0
36”
600
83
106
129
170
221
271
372.8
459.3
42”
150
63
81
98
130
168
207
266.2
349.9
42”
300
85
109
132
175
226
278
356.7
470.6
42”
600
107
137
166
220
285
350
448.7
592.8
LUBRICATING HANDWHEEL AND OPERATOR ASSEMBLY
Handwheel Operated Valves-
Connect a grease gun containing NLGI grade 2
petroleum base grease to the 1/8" Alemite type
grease fitting on the bearing housing. Pump in a
small amount of grease. DO NOT OVERFILL.
Bevel Gear Operators-
Bevel gear operators are supplied by other
manufacturers. Consult particular manufacturer's
instructions. If these are not available, lubricate
the same as Handwheel Operated Valves
above.
Motor Operated Valves-
Motor operators are supplied by other
manufacturers. Consult particular manufacturer's
instructions.
Lubricating Stem
1. Remove the stem protector and inspect the
stem thread for any damage.
2. Clean any visible debris prior to applying
grease to the stem thread, see Recommended
Lubricants and Sealants.
3. Cycle the valve to distribute the grease
throughout the threading and stem nut in the
operator.
4. If operation is smooth, remove any debris
build-up on the stem protector and reinstall onto
the operator.
Installation, Operation and Maintenance Manual 15 IOM-GRO-GATE-FABRICATED-G7
LUBRICATING SEATS
Grove “G7” Fabricated Gate Valves are
equipped with seat injection ports. For dry/gas
service, lubricate once a year.
1. Only use grease guns that are equipped with
a pressure gage.
2. Some seat sealants become very stiff or
viscous in cold weather. It may be difficult to
pump some sealants under these conditions.
It is recommended that the grease gun be kept
in a heated area until it is ready to be used. If
this is not possible, contact the local Cameron
Valves & Measurement service representative
for low temperature sealant recommendations.
3. Move the valve to the closed position.
4. Carefully, remove the safety caps on the seat
lubrication fitting using a wrench.
WARNING: Back up the seat grease fitting
using a wrench so only the safety cap will be
removed from the fitting. Carefully remove
the safety cap from the seat grease fitting.
NEVER remove the grease fitting with the
valve under pressure!
5. Connect the grease gun to the seat lubrication
fitting(s). (Both sets may be lubricated at the
same time).
6. Pump the sealant into the seat. Once the
pressure rises above the valve rated pressure,
hold for three (3) minutes to promote filling of the
grease grooves.
Note: Grease guns can develop pressures far
in excess of the valve working pressure. Use
only grease guns, which are equipped with
pressure gages. Do not exceed the valve
maximum allowable working pressure.
7. Stroke the valve to spread the sealant on the
seat surfaces. (Indicator rod should move
approximated 1" or 25 mm).
8. Release the pressure in the grease gun and
remove it from the grease fitting. The fitting ball
check should prevent the release of the valve
grease pressure.
9. Install the fitting safety cap and tighten
securely.
10. Repeat for the other seat. Both seats may be
lubricated at the same time, if desired.
RECOMMENDED LUBRICANTS AND SEALANTS
TRIM
NORMAL SEAT
LUBRICANT
STEM/BEARING
LUBRICANT
EMERGENCY
SEAT SEALANT
EMERGENCY
STEM PACKING
G-20
(Aromatic Hydrocarbons and
refined products, non-sour)
WKM #58G or
Val-Tex 700
NLGI Grade 2
Bearing Grease
WKM #58G
WKM #113 or Jim
Ray Tiger Pak "FF"
G-21
(Aromatic Hydrocarbons and
refined products, sour)
Val-Tex 700
NLGI Grade 2
Bearing Grease
WKM #102
WKM #109
G-23
(Low temperature produced
hydrocarbons, sour)
Val-Tex 50
WKM #1
WKM #103
WKM #109
Installation, Operation and Maintenance Manual 16 IOM-GRO-GATE-FABRICATED-G7
Figure 9 – Bucket-Type Gun,
Part Number K065189. Exact
configuration may vary from
illustration.
RECOMMENDED LUBRICANTS AND SEALANTS Continued
PRODUCT
MANUFACTURER
WKM #1
WKM #58G
WKM #102
WKM #103
WKM #109
WKM #113
WKM #115
Cameron Valves & Measurement
Operation Services
8820 Meldrum Ln
Houston, TX 77075
713-946-2122
Fax: 713-331-5813
Val-Tex 700
Val-Tex 50
Val-Tex
10600 Fallstone Road
Houston, TX 77009
800-627-9771
281-530-4848
Fax: 281-530-5225
Jim Ray Tiger Pak FF
Jim Ray
10645 Richmond Ave. #130
Houston, TX 77042
713-785-5055
Fax: 713-785-5534
Figure 8 – Screw/Prime Hand
Gun, Part Number 2122495-01.
Exact configuration may vary
from illustration.
Figure 10 – Adapter Fitting,
Part Number K296434.
Installation, Operation and Maintenance Manual 17 IOM-GRO-GATE-FABRICATED-G7
TROUBLESHOOTING
Trouble
Probable Cause
Remedy
Leakage is occurring around the
stem, yoke tube drain, or yoke tube
to bonnet joint.
The stem seal is leaking due to a
contaminated stem.
Cycle the valve several times.
The stem seal is leaking due to
damage or abnormal wear.
Close the valve to energize stem
backseat.
The stem seal is leaking due to
damage or abnormal wear.
Inject plastic packing as follows:
Remove the packing fitting screw
and install a packing injection gun1
loaded with the proper plastic
injectable. Refer to the
"Recommended Lubricants and
Sealants" table.
Using the packing gun, pump plastic
to energize the packing set. 4000-
5000 psig (275-345 barg) is usually
sufficient. DO NOT EXCEED 10,000
psig (690 barg).
WARNING: THE INJECTION
PRESSURE IS TWICE THE
HYDRAULIC GAUGE PRESSURE.
Hold for at least 3 minutes. Re-
pressurize, as needed.
Remove the packing gun.
Lubricate the packing fitting screw
thread with a good grade of bearing
grease and thread it into the fitting.
Tighten securely but do not exceed 7
ft-lbf (9.5 N-m) of torque.
See “Appendix” for more information.
The grease fitting or bleed plug is
leaking.
The safety cap or bleed plug screw is
loose.
Tighten the safety cap or bleed plug
screw.
The valve is leaking around the
bonnet to body joint.
The bonnet seal is leaking.
Ensure that the bonnet nuts are
tightened properly. Contact local
Cameron Valves & Measurement
service representative if leakage
persists.
A restriction is present in the valve
bore.
The gate is not properly aligned with
the seats.
HANDWHEEL OR BEVEL GEAR
OPERATED VALVES:
Open the valve fully by turning the
handwheel counter-clockwise.
Tighten securely.
MOTOR OPERATED VALVES:
Make sure the operator limit switches
are set correctly. Do not exceed
Maximum Allowable Stem Torque
and Thrust.
The valve is hard to operate.
The lubrication is not sufficient.
Lubricate the seats per the
“Lubricating Seats” section.
Remove the stem protector to clean
and grease the stem.
Increase torque within allowable
limit.
1Contact local Cameron Valves & Measurement Service Representative for current part number.
Installation, Operation and Maintenance Manual 18 IOM-GRO-GATE-FABRICATED-G7
TROUBLESHOOTING continued
Trouble
Probable Cause
Remedy
(continued)
The valve is hard to operate.
Ice is present in the yoke tube,
handwheel unit, or operator.
Apply heat to melt ice. (Do not
exceed 250°F)
Line bind is present. (Pipeline
bending moments distorting the
valve body).
Relieve the bind or moment on the
valve.
Excessive stem packing pressure
causing drag.
Relieve the excess packing pressure
through the injection fitting using
stinger tool.
The valve will not fully close.
Debris build up in the body.
Return valve to the open position.
Flush the body cavity through the
drain. See “Draining Valve” section.
Debris build up in the seats.
Flush the seat pockets with lubricant
per “Lubricating Seats” section.
Excessive stem packing pressure
causing drag.
Relieve the excess packing pressure
through the injection fitting using
stinger tool.
Motor operator will not actuate the
valve.
Improperly sized motor operator.
Replace with properly sized motor
operator.
Improperly wired electric operator.
Verify wiring following instructions
and schematics provided by the
operator manufacturer.
Valve operation is erratic.
The bearings need lubrication.
Lubricate the operator per the
manufacturer’s instructions.
The stem, bearing or gear unit is
broken or damaged.
Replace broken or damaged parts.
The valve seats will not seal.
Valve is not fully closed.
Fully close the valve. Turn the
handwheel CLOCKWISE.
Seat or seat seals are damaged.
Inject Seat Sealant per the
“Lubricating Seats” section. Replace
parts.
Installation, Operation and Maintenance Manual 19 IOM-GRO-GATE-FABRICATED-G7
APPENDIX
INJECTING PACKING
1. Grove “G7” Fabricated Gate Valves use a
self-adjusting stem seal identified by the
following tag on the packing fitting. These
require only periodic inspection.
2. Inspect the valve for evidence of stem
leakage. This might be determined by paint
discoloration around the bonnet-yoke tube
joint. If there is no evidence of leakage, no
maintenance is required.
3. If leakage is evident, inject plastic packing
as follows:
STICK METHOD
GUN METHOD
Note: Packing is not damaged by cold. However, keep plastic packing in a warm place (like a heated room
or vehicle cab) until ready for use to keep pliable.
• Remove the
injection stinger
from the packing
fitting
CAUTION:
Pressure may be
trapped in the
packing box
• Apply a good grade
of earing grease to
the threads
• Place a stick of packing into the fitting and
screw in the stinger until it seats.
• Repeat as necessary. Use screw torques
as follows:
▪ 3-4 ft-lb (40-50 in-lb, 4-5.5 N-m) for
WKM packings
▪ 4-5 ft-lb (50-60 in-lb, 5.5-7 N-m) for
thick packings
▪ Do not exceed 7 ft-lb (60 in-lb, 9.5 N-
m) as this may exceed the 10,000 psig
(689 barg) rating of the fitting
• Back out the screw until the threads show,
this allows the bail check to seat
CAUTION: Apply only enough packing to stop
the leak
• Remove the injection stinger from the packing
fitting. CAUTION: Pressure may be trapped in the
packing box
• Assemble the packing
gun with the appropriate
plastic packing
• Connect the gun to the
packing fitting
• Apply 4000-5000 psig (275-
345 barg) to the packing gun.
Thick packing may require
8000-9000 psi (551-620 bar).
CAUTION: The WKM style
packing gun applies twice the
hand pump pressure
• Hold for several minutes
• Add more plastic if the pressure drops
• Repeat until the packing pressure holds steady
• Do not exceed 10,000 psi (689 bar)
• Remove the packing gun
• Dig out any excess packing
from the packing fitting
• Apply a small amount of
bearing grease to the packing
fitting screw
• Install the packing fitting screw
and tighten

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