ENGINEERED & PROCESS VALVES
Installation, Operation and Maintenance Manual
WKM ®
Pow-R-Seal ® Gate Valve
WKM ®
ENGINEERED & PROCESS VALVES
TABLE OF CONTENTS
WKM ® POW-R-SEAL ® GATE VALVE
Bill of Materials
2”-4” Class 300-1500. ......................................................................... 3
6”-12” Class 300-900. ......................................................................... 4
6”-12” 1500, 14”-36” Class 300-900. ................................................. 5
Outside Packing Gland (OS&Y) .............................................................. 6
Scope ................................................................................................... 7
Nameplate Information ......................................................................... 7
Storage................................................................................................. 8
Installation ............................................................................................ 8
Hydrostatic Testing ............................................................................... 9
Operation ............................................................................................. 10
Routine Maintenance ............................................................................ 10
Draining Valve ...................................................................................... 11
Low Temperature Precautions ............................................................... 12
Lubricating Handwheel and Operation Assembly ................................... 13
Lubricating Seats ................................................................................... 13
Maintaining Vee Packing ....................................................................... 15
Trouble Shooting .................................................................................. 16
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ENGINEERED & PROCESS VALVES
BILL OF MATERIALS (2” - 4”) MODEL “M”
ITEM
DESCRIPTION
1.
Body
2.
Thermal Relief Valve System
2A.
Needle Valves
2B.
Female Connector
2C.
Check Valve
2D.
Male Connector
2E.
Tubing
2F.
Needle Valve Caution Tag
3.
Drain Fitting
4.
Seats
5.
Seat Skirts
6.
Gate and Segment Assembly
6A.
Gate
6B.
Segment
6C.
Springs
6D.
Spring Pins
7.
Bonnet Seal
8.
Bonnet
9.
Studs
10.
Nuts
11.
Packing Set
12.
Packing Retainer Nut
13.
Packing Retainer Lock Nut
14.
Bearings
15.
Stem Nut
16.
Packing Fitting Assembly
17.
Packing Plug
18.
Stem
19.
Stem Pin
20.
Bearing Housing
21.
Capscrews
22.
Bearing Housing Grease Fitting
23.
Weather Seal
24.
Handwheel
25.
Stem Protector
26.
Rod Wiper
27.
Indicator Rod
28.
Caution Tag for Trapped Pressure
29.
Nameplate
Figure 1 - WKM Pow-R-Seal Gate Valve 2”- 4” ASME Class 300 - 1500
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ENGINEERED & PROCESS VALVES
BILL OF MATERIALS (6” - 12”) MODEL “E1A” & “E1C”
ITEM
DESCRIPTION
1.
Body
2.
Thermal Relief Valve System
2A.
Needle Valves
2B.
Female Connector
2C.
Check Valve
2D.
Male Connector
2E.
Tubing
2F.
Needle Valve Caution Tag
3.
Vent, Drain and Seat Lube Fitting
4.
Seats
5.
Seat O-Rings
6.
Gate Seat Skirt
7.
Segment Seat Skirt
8.
Gate and Segment Assembly
8A.
Gate
8B.
Segment
8C.
Lever Lock Arm Pins
8D
Lever Lock Arms
9.
Bonnet Seal
10.
Bonnet
11.
Studs
12.
Nuts
13.
Packing Set
14.
Packing Fitting Assembly
15.
Packing Plug
16.
Stem
17.
Yoke Tube
18.
Yoke Tube Seal
19.
Packing Nipple
20.
Elbow 45°
21.
Hex Head Bolts
22.
Pull Plug
23.
Bearing Housing
24.
Washer
25.
Gasket
26.
Hex Head Bolts
27.
Bearing Housing Grease Fitting
28.
Bearings
29.
Stem Nut
30.
Stem Nut O-Ring
Figure 2 - WKM Pow-R-Seal Gate Valve 6”- 12”
31.
Handwheel
ASME Class 300 - 900
32.
Handwheel Keys
33.
Stem Protector Washer
34.
Stem protector
35.
Rod Wiper
Note: On Model “E1C” the Packing Set is located
36.
Indicator Rod
in the Bonnet and therefore the Packing Injec-
37.
Caution Tag for Trapped Pressure
tion Port is on the O.D. of the Bonnet.
38.
Nameplate
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ENGINEERED & PROCESS VALVES
BILL OF MATERIALS (6” - 12” 1500, 14” - 36” 300 - 900)
MODEL “E” & “E1C”
ITEM
DESCRIPTION
1.
Body
2.
Thermal Relief Valve System
2A.
Needle Valves
2B.
Female Connector
2C.
Check Valve
2D.
Male Connector
2E.
Tubing
2F.
Needle Valve Caution Tag
3.
Drain and Seat Lube Fittings
4.
Vent Fittings
5.
Seats
6.
Seat O-Rings
7.
Gate Seat Skirt
8.
Segment Seat Skirt
9.
Gate and Segment Assembly
9A.
Gate
9B.
Segment
9C.
Lever Lock Arm #1
9D.
Lever Lock Arm #2
9E.
Lever Lock Arm Pins
9F.
Lever Lock Shoe
9G.
Shoe Pins
10.
Bonnet Seal
11.
Bonnet
12.
Studs
13.
Nuts
14.
Packing Set
15.
Packing Fitting Assembly
16.
Packing Plug
17.
Stem
18.
Yoke Tube
19.
Yoke Tube Seal
20.
Studs
21.
Nuts
22.
Pull Plug
23.
Gasket
24.
Bevel Gear Operator
25.
Hex Head Bolts
26.
Stem Protector
27.
Rod Wiper
28.
Indicator Rod
29.
Caution Tag for Trapped
Figure 3 - WKM Pow-R-Seal Gate Valve 6”- 12” ASME Class 1500,
Pressure
14” - 36” 300 - 900.
30.
Nameplate
Note: On Model “E1C” the Packing Set is located in the Bonnet
and therefore the Packing Injection Port is on the small O.D. at
the top of the Bonnet.
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ENGINEERED & PROCESS VALVES
BILL OF MATERIALS OUTSIDE PACKING GLAND
(OPG OR OS&Y) OPTION
Figure 4 - Outside Packing Gland (OPG) Stem Seal Arrangement
ITEM
DESCRIPTION
1.
OPG Yoke Tube
2.
Studs
3.
Nuts
4.
Lock Washer
5.
Follow Plate
6.
Packing Gland
7.
Packing Rings
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ENGINEERED & PROCESS VALVES
SCOPE
This manual covers all bolted bonnet Pow-R-Seal
Outside packing gland stem seals are offered for high
Gate Valves. Drawings shown are typical. The design of
temperatures up to 1000°F (588°C).
specific valves may vary slightly from the drawings.
Pow-R-Seal Gate Valves do not depend on lubricant
The Pow-R-Seal Gate Valve is a premium through conduit
for a seal in normal operation. However, lubricant and
parallel expanding gate valve. The parallel expanding gate
sealants can be injected to promote smooth operation.
design provides a tight mechanical seal which is normally
Seat sealant can also be injected to affect a seal in an
unaffected by pressure variations. The full-bore design
emergency should the seats become damaged by
has the same pressure drop as an equivalent length of
foreign matter.
pipe and allows passage of all types of scrapers (pigs).
Seats with all metal seats are available in special trims.
The Pow-R-Seal Gate Valve is designed with positive stops
Because of the split gate design, it is possible for excess
that do not need adjustment. The valve can be repaired
body pressure to develop in the valve body cavity. A body
while in line (pressure removed and valved drained).
cavity thermal relief system is provided to relieve this
excess body pressure.
The stem is sealed either by Chevron packing or
spring-loaded lip seals. In an emergency, plastic packing
Pow-R-Seal Gate Valves are available in sizes, pressure
can be injected into the packing box to affect a tempo-
classes, materials and coatings that meet industry require-
rary seal while the valve is under pressure.
ments. 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
12
4.
API Class Designation
16
13
5.
Maximum Temperature in °F
1
11
6
7
6.
*Bill of Material Number
3
8
15
7.
Body Material Designation
4
9
8.
Stem Material Designation
5
10
17
9.
Gate Material Designation
10.
Seat Material Designation
Figure 5 - Typical Power-R-Seal Nameplate
11.
(Maximum Operating Pressure at 250°F - if Applicable)
12.
(API Monogram - if Applicable)
13.
Model Designation
14.
(Marking for Non-Standard End-to-End -
if Applicable)
15.
(License Number - if Applicable)
16.
Date of Manufacture
17.
(Impact Test Temperature - if Applicable)
( ) Descriptions in parenthesis may be left blank in some cases.
* Most important data for obtaining correct replacement parts.
Nameplate may vary.
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ENGINEERED & PROCESS VALVES
STORAGE
After WKM Pow-R-Seal Gate Valves are assembled and
or the stem adapter should be covered to
tested, the valves are left in the full open position,
avoid accumulation of water and debris.
seats and bores are greased and end protectors are
installed. These measures will provide protection for
If long-term storage is required, the valve should be
approximately six months. The following care should
conditioned by following Cameron procedure
be taken when storing valves:
X-150771-01. Ensure adequate end connection covers
are in place. Request a copy of X-150771-01 from
1.
Make sure the valve end connection covers
Cameron’s Valves & Measurement group.
remain in place during storage.
2.
If the valve does not have an operator and the
valve will be stored outside, the exposed stem
INSTALLATION
Install Pow-R-Seal Gate Valves into the line with the
Caution: Keep weld end valves open while installing/
preferred pressure flange end or weld end (marked
welding into the line. Weld slag created during the
with red paint from the factory) as the upstream side.
welding process could damage gate sealing surfaces.
When handling or installing the valve, keep the valve
in the full open position whenever possible to prevent
1.
Use solvent to clean grease or rust inhibitor
foreign matter damage to the gate and seat
from the gate and/or bore of the valve.
sealing surfaces. The valve should be lifted in such
2.
Make sure the line and valve weld bevels are
a way that the body supports the load or use lifting
properly aligned, and will not bind the valve.
lugs, if provided.
3.
Electric welding equipment is preferred for all
installations. However, if only
Caution: Do not use handwheels or other protrud-
oxygen-acetylene
ing parts of the valve, gearbox or actuator to lift the
welding equipment is available, extreme
valve. During handling, use care to avoid damaging
caution should be taken regarding excess
the end connection faces, fittings and bypass relief
welding temperature to prevent damage to
systems. The end connection necks are suitable places
sealing components of the valve.
to attach lifting slings, if lifting lugs are not on the
4.
Weld with the gate in “Full Open” position.
valve.
5.
Make sure temperature of the body/seat area
does not exceed 250°F. (Check with Tempil
Flanged-End valves may be bolted into line using two
stick or equivalent).
open or boxed end wrenches. Power wrenches may be
6.
Avoid rapid application of excess welding
required for larger valves. Make sure the line flanges
material. Weld each end of the valve with a
are properly aligned and will not distort or bind the
continuous bead using a 1/8” maximum
valve. Use new flange gaskets.
diameter electric welding rod.
7.
Keep the valve in the “Full Open” position
1.
Bolt and nut threads should be lubricated to
until the line has been thoroughly cleaned of
obtain proper loading of bolts.
weld slag in the valve bore and line (by
2.
Finger-tighten all nuts first.
pigging and/or flushing) before changing the
3.
Tighten bolts, using the crisscross method and
position of the gate.
torque each bolt to ASME or gasket
manufacture’s specifications.
Pow-R-Seal Gate Valves in liquid service must have a
body thermal relief system (needle valves, if present,
Butt Weld-End Valves should be welded into the line
must be in the open position prior to operation of
by qualified welders, using qualified procedures.
valve) installed on the valve.
Cameron Valves & Measurement recommends that all
welding procedures and welders be qualified
Caution: Failure to install a properly set body thermal
per ASME Section IX.
relief system on the valves in liquid service may cause
rupturing of the body resulting in catastrophic release
of pressure.
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ENGINEERED & PROCESS VALVES
HYDROSTATIC TESTING
Pow-R-Seal Gate Valves in liquid service must have a
4.
Upon completion of the hydrostatic testing,
body thermal relief system (needle valves, if present,
the valve should be returned to the fully open
must be in the open position prior to operation of
position before removing the test fluid from
valve) installed on the valve.
the piping system. The test fluid in the
body cavity can be drained through the body
Caution: Failure to install a properly set body thermal
drain port located in the lower portion of the
relief system on the valves in liquid service may cause
valve body. (See Draining Valve, Page 13).
rupturing of the body resulting in catastrophic release
of pressure.
5.
Close the valve body bleed fitting and return
the valve to the required operating position,
1.
The valve should be in a fully open position
either fully open or fully closed.
when the injection of test fluid begins.
This will allow any pipeline debris to be
6.
If the valve is equipped with seat injection
flushed through the valve bore and out of
fittings, the valve seat pockets should be filled
the piping.
with an approved valve lubricant to displace
any test fluid from behind the seats.
2.
Once the piping system has been purged of
debris and the system has been filled
7.
Some WKM T-11 or T-102 trim valves
completely with the test fluid, the gate
having Vee packing should be repacked after
should be placed in the partially open
hydrostatic testing with water. Follow the
position to allow test fluid into the body cavity
procedure in the Troubleshooting section of
of the valve.
this manual for repacking the stem seal. Use
WKM #113 or Jim Ray TIGER PAK FF
3.
The valve is now ready to be hydrostatically
plastic packing.
pressure tested.
Caution: Do not exceed pressures listed below. Test
pressures are per API 6D and are not operating
pressures. The Maximum Allowable Operating Pres-
sure (MAOP) is marked on the nameplate.
Pressure
Hydrostatic Shell Hydrostatic Seat
Class
psig (barg)
psig (barg)
150
425 (29.3)
300 (20.7)
300
1100 (75.9)
800 (55.2)
600
2175 (150)
1600 (110)
900
3250 (224)
2400 (166)
1500
5400 (372)
4000 (275)
2500
9000 (620)
6600 (455)
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ENGINEERED & PROCESS VALVES
OPERATION
The Pow-R-Seal Gate Valve may be operated with a
CLOCKWISE. The valve is OPENED by turning the
handwheel or may be power actuated. With either
handwheel COUNTER-CLOCKWISE until it contacts
mode of actuation, open and close valve completely.
the stop. The indicator rod at the top of the valve
DO NOT THROTTLE FLOW. The valve, in good
will move up (away from the valve bore), as the
condition, will seal pressures up to the maximum
handwheel is turned COUNTER-CLOCKWISE.
allowable working pressure as a block valve, single
block-and-bleed valve or a double-block-
When valves are equipped with power actuators,
and-bleed valve.
the movement of the indicator rod will indicate if
the valve is being opened or closed. Make sure all
Valves equipped with handwheels are CLOSED by
accessories recommended by the actuator
turning the handwheel CLOCKWISE until it becomes
manufacturer are installed before valve actuator
tight. Tighten securely to mechanically energize
installation. Should any maintenance be necessary,
the seal. DO NOT BACK OFF THE HANDWHEEL. The
obtain the part number from the unit’s nameplate
indicator rod at the top of the valve will move down
and contact Cameron Valves & Measurement or the
(towards the valve bore), as the handwheel is turned
nearest representative.
ROUTINE MAINTENANCE
The following outlines the minimum scheduled
1.
Inspect relief systems at least twice a year
maintenance required for Pow-R-Seal Gate Valves
for any visual abnormalities such as damage
to promote trouble-free service and long life. Some
that may prevent the system from
applications may require more maintenance.
functioning properly. Repair or replace, as
Visually inspect every six months. See trouble
required to correct abnormalities.
shooting section (page 13) for temporary solution to
problems. Operate the valve once a month, if
2.
Check valves shall be tested periodically to
practical. A full open-close cycle is preferable.
verify proper function. Follow local piping
Operate a partial cycle as a minimum.
codes and plant/facility maintenance and
safety procedures for the testing frequency.
Caution: Verify compatibility of any sealant,
Cameron Valves & Measurement
lubricant, or anti-freeze with the trim of the valve
recommends testing check valves using the
and product in the line.
same schedule for relief valves per ASME
B31.4 in the absence of local testing
Thermal Relief System Maintenance
frequency requirements. Make sure needle
Pow-R-Seal Gate Valves equipped with a thermal
valves in thermal relief systems are open
relief system.
before returning the valve to service.
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ENGINEERED & PROCESS VALVES
DRAIN VALVE
After lengthy service, there is a possibility of water,
pressure will blow through the safety holes in the
line scale, sediment or other foreign matter collecting
cap.) Back-up the seat grease fitting using a wrench
in the lower body cavity. It is advisable to periodically
so only the safety cap will be removed from the
drain the valve to discourage development of
fitting. Carefully remove the safety cap from the seat
conditions that can possibly lead to valve damage or
grease fitting. NEVER remove the grease fitting with
impair the operation of the valve. If draining is not
the valve under pressure!
regularly scheduled, it is strongly recommended to
drain the valve at these times:
Carefully remove the safety cap of the lower drain
grease fitting. Contact your local Cameron Valves &
1.
After hydrostatic testing.
Measurement representative for further assistance, if
needed. Back out the stinger of the pressures releas-
2.
After cleaning the line.
ing too until it stops. Install the pressure releasing tool
onto the uncapped grease fitting. Carefully screw the
3.
When valve cannot be fully opened or closed
stinger of the releasing tool - (until the ball check
(foreign matter in the bottom of valve
in the grease fitting is pushed off its seat). This will
can not only prevent placing valve in a fully
allow the valve to drain or to release body pressure.
closed position, it can also cause permanent
After completion, back out the stinger of the pressure
damage to the internal sealing surfaces). A
releasing tool to allow the ball check in the grease
safety pressure releasing tool is required to
fitting to reseat and permit easy removal of the
simplify the procedure of releasing body
pressure releasing tool. Replace safety cap on the
pressure or draining the valve. To release
lower drain grease fitting.
body pressure or to drain valve, first place the
valve in closed position.
Warning : To avoid possibly being struck by liquid or
foreign solid matter, position yourself so the outlet
port of the grease fitting is pointing safely away from
you. (If the ball check is not holding pressure,
VENT CAP
1 1/4” HEX
VENT CAP
1” - 14 UNS
1” TO 5/16”
WRENCH HEX
BALL
POSITIVE FLOW
BALL SUPPORT
SPRING
1/4” TO 1” NPT THREAD
HEAVY-DUTY
RADIAL RIVET CRIMP
GREASE FITTING
PRESSURE RELEASE TOOL
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ENGINEERED & PROCESS VALVES
LOW TEMPERATURE PRECAUTIONS
Prior to exposure to freezing temperatures it is highly
It is also advisable to inject a sufficient amount of
recommended the valve be drained.
valve lubricant into the grease fittings of the valve
and operator (if present) prior to extended cold
Water that may be trapped in the body cavity could
temperatures exposure.
freeze and impair the operation of the valve o
damage the valve.
Trapped water should be drained from stem
extensions. Some stem extensions in the field are
If the valve has a grease fitting in the lower drain,
equipped with plastic plugs that can be removed to
a sufficient amount of anti-freeze injected into the
drain trapped water from the piped extension.
body cavity via the lower drain grease fitting will
prevent accumulated water from freezing.
VOLUME OF ANTI-FREEZE (ETHYLENE GLYCOL) TO PREVENT FREEZING
Minimum Expected
18°F / -8°C
13° / -11°C
7°F / -14°C
8°F / -22°C
28°F / -33°C
Temperature Value
(18%)
(23%)
(28%)
(37%)
(48%)
(Percent Anti-Freezed)
2”
0.3 Gallons
0.3 Gallons
0.4 Gallons
0.6 Gallons
0.7 Gallons
(1.0 Liters)
(1.3 Liters)
(1.6 Liters)
(2.1 Liters)
(2.7 Liters)
2 ½”
0.3 Gallons
0.3 Gallons
0.4 Gallons
0.6 Gallons
0.7 Gallons
(1.0 Liters)
(1.3 Liters)
(1.6 Liters)
(2.1 Liters)
(2.7 Liters)
3”
0.4 Gallons
0.5 Gallons
0.6 Gallons
0.7 Gallons
1.0 Gallons
(1.4 Liters)
(1.7 Liters)
(2.1 Liters)
(2.8 Liters)
(3.6 Liters)
4”
0.5 Gallons
0.7 Gallons
0.8 Gallons
1.1 Gallons
1.4 Gallons
(2.0 Liters)
(2.6 Liters)
(3.2 Liters)
(4.2 Liters)
(5.5 Liters)
6”
1.0 Gallons
1.2 Gallons
1.4 Gallons
1.9 Gallons
2.4 Gallons
(3.8 Liters)
(4.5 Liters)
(5.3 Liters)
(7.2 Liters)
(9.1 Liters)
8”
1.8 Gallons
2.3 Gallons
2.8 Gallons
3.7 Gallons
4.8 Gallons
(6.8 Liters)
(8.7 Liters)
(10.6 Liters)
(14.0 Liters)
(18.2 Liters)
10”
2.7 Gallons
3.5 Gallons
4.2 Gallons
5.6 Gallons
7.2 Gallons
(10.2 Liters)
(13.1 Liters)
(15.9 Liters)
(21.0 Liters)
(27.3 Liters)
12”
4.0 Gallons
5.1 Gallons
6.2 Gallons
8.1 Gallons
10.6 Gallons
(15.0 Liters)
(19.2 Liters)
(23.3 Liters)
(30.8 Liters)
(40.0 Liters)
14”
5.4 Gallons
6.9 Gallons
8.4 Gallons
11.1 Gallons
14.4 Gallons
(20.4 Liters)
(26.1 Liters)
(31.8 Liters)
(42.0 Liters)
(54.5 Liters)
16”
7.4 Gallons
9.4 Gallons
11.5 Gallons
15.2 Gallons
19.7 Gallons
(27.9 Liters)
(35.7 Liters)
(43.5 Liters)
(57.4 Liters)
(74.5 Liters)
18”
9.9 Gallons
12.7 Gallons
15.4 Gallons
20.4 Gallons
26.4 Gallons
(37.5 Liters)
(48.0 Liters)
(58.3 Liters)
(77.0 Liters)
(100 Liters)
20”
12.4 Gallons
15.9 Gallons
19.3 Gallons
25.5 Gallons
33.1 Gallons
(47.0 Liters)
(60.0 Liters)
(73.1 Liters)
(96.6 Liters)
(125 Liters)
22”
14.8 Gallons
18.9 Gallons
23.0 Gallons
30.3 Gallons
39.4 Gallons
(55.9 Liters)
(71.4 Liters)
(86.9 Liters)
(115 Liters)
(149 Liters)
24”
18.0 Gallons
23.0 Gallons
28.0 Gallons
37.0 Gallons
48.0 Gallons
(68.1 Liters)
(87.1 Liters)
(106 Liters)
(140 Liters)
(182 Liters)
26”
22.5 Gallons
28.8 Gallons
35.0 Gallons
46.3 Gallons
60.0 Gallons
(85.2 Liters)
(109 Liters)
(132 Liters)
(175 Liters)
(227 Liters)
28”
27.7 Gallons
35.4 Gallons
43.1 Gallons
57.0 Gallons
73.9 Gallons
(105 Liters)
(134 Liters)
(163 Liters)
(216 Liters)
(280 Liters)
30”
34.6 Gallons
44.2 Gallons
53.8 Gallons
71.0 Gallons
92.2 Gallons
(131 Liters)
(167 Liters)
(204 Liters)
(269 Liters)
(349 Liters)
36”
96.3 Gallons
123 Gallons
150 Gallons
198 Gallons
257 Gallons
(365 Liters)
(466 Liters)
(567 Liters)
(749 Liters)
(972 Liters)
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ENGINEERED & PROCESS VALVES
LUBRICATING HANDWHEEL AND OPERATOR ASSEMBLY
Handwheel Operated Valves - Connect a grease gun
Warning: Back-up the seat grease fitting using a
containing NLGI grade 2 petroleum base grease to
wrench so only the safety cap will be removed from
the 1/8” Alemite type grease fitting on the bearing
the fitting. Carefully remove the safety cap from the
housing. Pump in a small amount of grease. DO NOT
seat grease fitting. NEVER remove the grease fitting
OVERFILL.
with the valve under pressure!
Bevel Gear Operated Valves - Bevel gears are supplied
5.
Connect the grease gun to the seat lubrication
by other manufacturers. Consult particular
fitting(s). (Both sets may be lubricated at the
manufacturer’s instructions. If these are not available,
same time)
lubricate the same as Handwheel Operated Valves
6.
Pump the sealant into the seat. Once the
above.
pressure rises above the valve rated pressure,
hold for three (3) minutes to promote filling
Motor Operated Valves - Motor operators are
of the grease grooves.
supplied by other manufacturers. Consult particular
manufacturer’s instructions. Lubricating Seats (6” and
NOTE: Grease guns can develop pressures far in
larger valves equipped with seat sealant ports).
excess of the valve working pressure. Use only grease
Lubricate once a year.
guns, which are equipped with pressure gages. Do
not exceed the valve maximum allowable
1.
Only use grease guns that are equipped with a
working pressure.
pressure gage.
2.
Some seat sealants become very stiff or viscous
7.
Stroke the valve to spread the sealant on the
in cold weather. It may be difficult to pump
seat surfaces. (Indicator rod should move
some sealants under these conditions.
approximated 1” or 25 mm.)
It is recommended that the grease gun
8.
Release the pressure in the grease gun and
be kept in a heated area until it is ready to be
remove it from the grease fitting. The fitting
used. If this is not possible, contact your local
ball check should prevent the release
Cameron Valves & Measurement
of the valve grease pressure.
representative for low temperature sealant
9.
Install the fitting safety cap and
recommendations.
tighten securely.
3.
Move the valve to the closed position.
10.
Repeat for the other seat. Both seats may be
4.
Carefully, remove the safety caps on the seat
lubricated at the same time, if desired.
lubrication fitting using a wrench.
RECOMMENDED LUBRICANT & SEALANT
Trim
Normal Seat Lubricant
Emergency Seat Sealant
Bearing Lubricant
Stem Packing
T-11, T-102, T-94
WKM #58G
WKM #58G
NLGI Grade 2
WKM #113
(Aromatic Hydrocarbons and
or VAL-TEX 700
Bearing Grease
or JIM RAY
refined products)
TIGER PAK FF
T-24, T-10
VAL-TEX 700
WKM #102
NLGI Grade 2
WKM #109
(Sour Oil and Gas,
Bearing Grease
Waterflood)
T-08, T07
NONE
NONE
NLGI Grade 2
WKM #115
(Geothermal water and Steam)
Bearing Grease
T-30, T-31
NONE
NONE
NLGI Grade 2
NONE
(High temperature steam and
Bearing Grease
hydrocarbon products)
T-36, T-37
VAL-TEX 50
WKM #103
WKM #1
WKM #109
(Low temperature produced
hydrocarbons)
T-88
NLGI Grade 2
NLGI Grade 2
NLGI Grade 2
JIM RAY
(Anhydrous Ammonia Products)
Bearing Grease
Bearing Grease
Bearing Grease
TIGER PAK A
Installation, Operation and Maintenance Manual
13
02/2011 / IOM-WKM-GATE-PRS-01
ENGINEERED & PROCESS VALVES
Product
Manufacturer
WKM 1
Cameron Valves & Measurement
WKM 58G
3250 Briarpark Drive, Suite 300
WKM 102
Houston, TX 77042
WKM 103
281.499.8511
WKM 109
1.800.323.9160
WKM 113
281.261.3615 (fax)
WKM 115
Val-Tex 700
Val-Tex
Val-Tex 50
10600 Fallstone Road
Houston, TX 77009
800.627.9771
281.530.4848
281.530.5225 (fax)
Jim Ray Tiger Pak FF
Jim Ray
Jim Ray Tiger Pak A
10645 Richmond Ave. #130
Houston, TX 77042
713.785.5055
713.785.5534 (fax)
Figure 11 - Screw/Prime Hand Gun, Part
Number 2122495-01. Exact configuration
may vary from illustration.
Figure 12 - Bucket-Type Gun, Part
Number K065189. Exact configuration
may vary from illustration.
Figure 13 - Adapter Fitting, Part
Number K296434
Installation, Operation and Maintenance Manual
14
02/2011 / IOM-WKM-GATE-PRS-01
ENGINEERED & PROCESS VALVES
Maintaining Vee-packing
(If so equipped) - Once a year or more often
around the bonnet-yoke tube joint. If there is no
as required.
evidence of leakage, no maintenance is required. It
is often beneficial to add one stick of packing once
1. Valves equipped with Chevron Vee Packing may
a year to help keep the packing pliable and prevent
require periodic inspection and maintenance to
future problems. (Couple of “sticks” for larger valves)
preclude stem leakage. This is particularly important if
the valves are in service at
4. If leakage is evident, inject plastic packing. See the
temperatures above 250°F (121°C).
Trouble Shooting Section.
2. Other designs use a self-adjusting
stem seal and require only
NOTICE
periodic inspection.
THIS VALVE IS
ASSEMBLED USING A
SELF ENERGIZED STEM
SEAL. INJECT PLASTIC
3. Inspect the valve for evidence of
PACKING ONLY IN
THE EVENT OF A
stem leakage. This might be
STEM SEAL LEAK.
determined by paint discoloration
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
  • Remove the injection stinger from the packing fitting.
  • the packing fitting.
    CAUTION : pressure may be trapped in the packing box
    CAUTION : pressure may be trapped
    in the packing box
  • Assemble the packing gun with the
  • appropriate plastic packing
  • Apply a good grade of earing
  • grease to the threads
  • Connect the gun to the
  • packing fitting
  • Place a stick of packing Into
  • the fitting and screw in the stinger
  • Apply 5500-7500 psi (379-517 bar)
  • until it seats
    to the packing gun. Thick
    packings may require 8000-9000
  • Repeat as necessary. Use
  • psi (551-620 bar)
    screw torques as follows:
    CAUTION : The WKM style packing gun
    applies twice the hand pump pressure
  • 3-4 ft-lb (40-50 in-lb, 4-5.5 N-m) for WKM packings
  • Hold for several minutes
  • 4-5 ft-lb (50-60 in-lb, 5.5-7 N-m) for thick packings
  • Add more plastic if the pressure drops
  • 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
  • Repeat until the packing pressure
  • holds steady
  • Back out the screw until the threads show. This allows the bail
  • check to seat
  • Do not exceed 10,000 psi (689 bar)
  • CAUTION : Apply only enough packing to stop the leak
  • 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
  • Installation, Operation and Maintenance Manual
    15
    02/2011 / IOM-WKM-GATE-PRS-01
    ENGINEERED & PROCESS VALVES
    TROUBLESHOOTING
    Trouble
    Probable Cause
    Remedy
    The stem seal is leaking due to a contaminated
    Cycle the valve serveral times.
    stem.
    Leakage is occurring around the stem, yoke tube
    The stem seal is leaking due to dammage or
    ALL VALVES EXCEPT THOSE WITH
    OUTSIDE
    drain, or yoke tube to bonnet joint
    abnormal wear.
    PACKING GLANDS (OPG/OS&Y)
    Inject plastic packing as follows:
    Remove the packing fitting screw and install a
    packing injection gun 1 loaded with the proper
    plastic injectable. Refer to the
    “Recommeded Lubricants and Sealants” (chart).
    Using the packing gun, pump plastic to energize
    the packing set. 4000-5000 psig (275-345 barg) is
    usually sufficient. DO NOT EXCEED10,000 psig (690
    barg)
    Leakage is occurring around the stem, yoke tube
    The stem seal is leaking due to damage or abnor-
    WARNING : THE INJECTION PRESSURE IS
    drain, or yoke tube to bonnet joint.
    mal wear.
    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. Thread it into the
    fitting.Tighten securely but do not exceed 7 ft-lbf
    of torque.
    (9.5 N-M).
    VALVES WITH OUTSIDE PACKING
    GLANDS (OPG)
    Tighten the gland bolts in a alternating crossing
    pattern to stop the leak. Do not over tighten.
    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 bonnet to
    The bonnet seal is leaking.
    Insure that the bonnet nuts are tightened prop-
    body joint.
    erly. Call CAMERON VALVES &
    MEASUREMENT 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.
    DO NOT BACK OFF THE HANDWHEEL.
    MOTOR OPERATED VALVES: Make sure the
    operator limit switches are set correctly.
    The valve will not open
    The valve is pressure locked 2 .
    Vent the body pressure by using a pressure
    or close.
    releasing tool on one of the body vent fittings.
    The lubrication is not sufficient.
    Lubricate the bearings, operator, and/or seats
    per the Routine Maintenance Section. Lubricate
    the operator per the manufacturer’s instructions.
    The valve is hard to
    operate.
    Ice is present in the yoke tube, handwheel unit, or
    Apply heat to melt ice.
    operator.
    Line bind is present. (Pipeline bending
    Relieve the bind or moment on the valve.
    moments distorting the valve body).
    (continued next page)
    Installation, Operation and Maintenance Manual
    16
    02/2011 / IOM-WKM-GATE-PRS-01
    ENGINEERED & PROCESS VALVES
    Trouble
    Probable Cause
    Remedy
    (continued)
    (continued)
    (continued)
    Improperly sized motor operator.
    Replace with properly sized motor operator.
    Motor operator will not
    Improperly wired electric operator.
    Verify wiring following instructions and schemat-
    actuate valve.
    ics provided by the operator
    manufacturer.
    The bearings need lubrication.
    Lubricate bearings per the Routine Maintenance
    Section.
    Valve operation is erratic.
    The bearing or gear unit is broken
    Replace broken or damaged parts.
    or damaged.
    Valve is not fully closed.
    Fully close the valve. Turn the handwheel CLOCK-
    WISE. DO BACK OFF
    The valve seats will not
    THE HANDWHEEL.
    seal.
    Seat or seat seals are damaged.
    Lubricate seats per Routine Maintenance Section.
    Replace parts.
    1 Contact loacal Cameron Valves & Measurement Representative for current part number
    2 Pressure locked is a condition that may exist in any double sealing gate valve when the body cavity pressure greatly exceeds line pressure. It occurs only in the
    full open or full closed position and indicates that the sealing surfaces are in good condition.
    Installation, Operation and Maintenance Manual
    17
    02/2011 / IOM-WKM-GATE-PRS-01