Cameron Type 31 Welded Body Ball Valve

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Installation, Operation and Maintenance Manual

Cameron Type 31 Welded Body Ball Valve

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Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Publication TC1411-A Published August 1999

© Cooper Cameron Corporation, Cooper Cameron Valves Division, 1999. All rights reserved.

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Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Table of Contents Principle Components ...................................... 4 Overview ........................................................... 5 Nameplate Information .................................... 5 Storage .............................................................. 5 Installation ........................................................ 6 Maintenance ..................................................... 9 Trouble Shooting ............................................ 11 Stem Designs ................................................... 18

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Principle Components 1 2 3

4 5

6 7 5 8 9

10

11

Figure 1 - Cooper Cameron Valves' Cameron Welded Body Ball Valve components.

ITEM 1 2 3 4 5 6 7 8 9 10 11

DESCRIPTION Keyed shaft Upper stem seal* Upper body Lower stem seal Stem bearing Dog Ball Seat ring Lip seal End connection Lower body

*Details of stem are on pages 18 and 19.

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Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Cameron Welded Body Ball Valve Overview One of the most trusted valves in the petroleum industry,Cooper Cameron Valves Welded Body Ball Valve combines the strength of forged components with a lightweight and compact spherical design. Cameron Welded Body Ball Valves satisfy ANSI 150 through 2500 (PN 20 through PN 420) and API 2000 through 5000 standards. Made of forged steel to assure uniform fine grain structure and toughness, they may be specified in sizes from 2” to 56” (DN 50 to DN 1400). Engineered for heavy-duty

service, and minimal maintenance, the Cameron Welded Body Ball Valve is commonly selected for a number of applications. The distinctive design of the Cameron Welded Body Ball Valve gives it maximum strength and minimum weight as well as maximum resistance both to pipeline pressure and stresses. The compact, spherical design also eliminates body flanges, thus reducing overall size and leak paths.

Nameplate Information ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14

STAMP Nominal valve size x actual bore size. Maximum temperature Minimum temperature Body material symbol Seat insert material symbol Assembly part number Valve length API Class designation Maximum working pressure Maximum operating pressure Seat material symbol Ball material symbol Valve assembly serial number Month and year of manufacture Figure 2 - Typical valve nameplate.

Storage The valves are conditioned for a storage period of 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 already installed and the valve will be stored outside, the open stem extension or the stem adapter should be covered to avoid water buildup.

3. If long-term storage is required, the valve should be conditioned using a corrosion inhibitor and end connection covers. Follow the guidelines found in Cameron Engineering Bulletin 476B for long term storage. Obtain a copy from your Cooper Cameron Valves Representative.

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Installation Handling of Valves 1 . The valve should be lifted in such a way that the body supports the load. Caution: The journal and the end connection necks are suitable places to attach lifting slings. Never use handwheels or other protruding parts of the gearbox or actuator not designated for this purpose. 2 . If the valve is equipped with lifting lugs, these should be used for handling. 3 . The end protector covers should be kept in place on the end connections during all handling. Remove only during final installation of the valve.

Figure 3 - Correct valve lifting using end connection necks.

Caution: During handling, protect the end connection faces and fittings against damage from the lifting devices. Failure to cover faces and fittings could cause damage to the valve.

Position of Valve

Figure 4 - Correct lifting using the valve lifting lugs.

The ball valve may be installed in any position. Either end of the valve may be installed as the upstream end.

Protection of Ball Caution: The ball should be fully open during the installation of the valve. Failure to keep the ball fully open during installation could cause damage to the valve. If the ball must remain in the closed position during installation of the valve, coat the exposed surfaces of the ball with grease. This will protect the plug from damage due to weld splatter. Caution: Do not leave the valve in the partially open position for an extended period of time.

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Caution: A weld end valve without pup pipes should never be installed in the closed position.

Welding Instructions When preheating, welding or stress relieving, body temperatures must not exceed 4000F (2000C) at any point beyond 3” (75 mm) from the weld. Use tempil sticks to check temperatures. Before Cameron ball valves are welded into final position in the pipeline, cover the valve seal areas (ball-to-seat area and seat-to-end connection area) with 1” wide masking tape from the 3 o’clock to the 9 o’clock position. This will help prevent any foreign material from becoming lodged in these areas. The piping system should also be pigged before operation or pressure testing to remove any foreign material from the pipeline.

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Hydrostatic Testing When Cameron ball 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 surfaces and seat seals inside the valve. 1. Valve should be in the fully open position when the injection of test fluid 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 ball valve should be placed in the partially open position (approximately 10o from the fully open position). This allows test fluid into the body cavity of the valve. 3. The valve is now ready to be pressure tested. 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 on the lower portion of the valve body. 5. Once the valve and piping system have been pigged and customer product is injected into the piping system, the valve should be moved to the partially open position (approximately 10o from the fully open position). Any remaining test fluid trapped in the valve body cavity can then be vented through the body bleed plug, located on the lower portion of the valve body. If the valve has been fitted with a stem extension, the vent fitting will be located below the mounting flange on top of the extension. 6. Opening the body bleed fitting will force trapped test fluid out of the body cavity. Keep the bleed plug open until all fluids have been exhausted through the body bleed plug. 7. Close the valve body bleed fitting and return the valve to the fully open position or the required operating position. 8. The valve seat pockets should be filled with an approved valve flush product to displace any test fluid. Refer to Routine Seat Cleaning which appears on page 10.

Specific instructions for each design should be obtained from the gear / actuator manufacturer. 1. Make sure the valve is in the fully open or closed position and position the actuator to match. 2. Depending on the valve stem and the actuator/ gear mounting kit, it is possible that the actuator may be installed in multiple positions. If this is the case, determine where the customer desires the handwheel or actuator control panel and install it accordingly. (A thin layer of antiseeze on the valve stem is recommended.) 3. Once the operator is mounted, secure it with the appropriate bolts. If the bolt holes do not line up, slightly operate to the open or closed to match the mounting flange. If you are unable to operate the operator, performing steps 2 and 3 of Setting Stops may need to be conducted. 4. It is now necessary to set the operator stops as outlined in the following section.

Setting Stops Gear Operator with Stops 1. Make sure that operating the valve to the fully open and fully closed position will not disrupt current operation of line. 2. Loosen the open and closed stopscrew locknuts. 3. Turn stopscrews counter–clockwise to increase gear travel. 4. Operate the valve to the fully open position. 5. Utilize the stem stop viewports to verify valve position. (Refer to Open and Closed Viewports on page 9.) 6. Turn the open stopscrew clockwise until it stops, then tighten the locknut. If the stopscrews will not turn, repeat steps 3 and 4. 7. To set the closed stop, conduct steps 3 – 6, operating the valve to the closed position and utilize the closed stop.

Mounting the Gear/Actuator To mount a gear or power operator on a valve, use the following guidelines. Note: The guidelines given are for typical gear and actuator designs.

Figure 5 - Typical gear box with stops

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Rotary Vane Style Operator (4 Bar Type) 1. Make sure that operating the valve to the fully open and fully closed position will not disrupt current operation of line. 2. Loosen the open and closed stopscrew locknuts. 3. Turn stopscrews clockwise to increase travel. 4. If equipped with a manual override, use it to operate the valve to the fully open position. 5. Check the stem stop viewports to verify valve position. (Refer to Open and Closed Viewports on page 9.) 6. Turn the open stopscrew counter-clockwise until it stops, and tighten the locknut.

7. If the stopscrews will not turn repeat steps 3 and 4. 8. To set the closed stop, repeat steps 3 – 6, operate the valve to the closed position and use the closed stops.

Caution: Once the stop makes contact with the vane, do not continue to turn the screw.Continuing to turn the screw could move the valve off the stops. Figure 6 - Rotary Vane-style operator

Scotch Yoke Style Operator 1. Make sure that operating the valve to the fully open and fully closed position will not disrupt current operation of line. 2. Loosen the open and closed stopscrew locknuts. 3. Turn stopscrews counter–clockwise to increase piston travel. 4. If equipped with a manual override, use it to operate the valve to the fully open position. 5. Check the stem stop viewports to verify valve position. (Refer to Open and Closed Viewports on page 9.) 6. Turn the open stopscrew clockwise until it stops, and tighten the locknut.

7. If the stopscrews will not turn repeat steps 3 and 4. 8. To set the closed stop, repeat steps 3 – 6, operating the valve to the closed position and then using the closed stops.

Caution: Once the stop makes contact with the vane, do not continue to turn the screw. Continuing to turn the screw could move the valve off the stops. Figure 7 - Scotch Yoke-style operator

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Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Open and Closed Viewports Once the pipe plug and relief plug are removed from the valve mounting flange, the position of the keyshaft stop relative to the valve stops can be observed on valves with nominal stem sizes of 3"and larger. The valve is fully opened when the keyshaft stop butts against the valve stop as viewed through the "open viewport" and is fully closed when the keyshaft stop butts against the valve stop as viewed through the “closed viewport". Figure 8 shows the viewport locations for valves with a 3" stem size and figure 9 shows the viewport locations for valves with 4"and larger stem sizes.

Figure 8 - Open and closed viewport location for valves with 3" stem size; Valve shown in open position.

Operating Times

Figure 9 - Open and closed viewport location for valves with 4" and larger stem sizes; Valve shown in open position.

Longest Operating Time = 5 x Valve nominal bore (i.e., 5 seconds per inch of nominal bore)

*

Quick Operating Time Opening or closing a valve quickly induces loads in addition to the normal torsion load. It is therefore necessary to limit valve operating times in order to prevent over stressing of the valve. Valves can be safely operated with an operating time given by the formula: *

Quick operating time =

Valve nominal bore 2

If a faster operating time is required, please call your Cooper Cameron Valves Representative.

Longest Operating Time When the valve is being operated, the seat face is exposed. Therefore, to minimize the amount of time in which the seat face is exposed, Cooper Cameron Valves recommends a maximum operating time as follows:

The time is in seconds and the bore size is in inches.

*

Caution: Failure to follow these operating times could cause damage to the valve.

Maintenance Cooper Cameron Valves' Cameron Welded Body Ball Valve requires a minimum of maintenance. In order to optimize the life of the valve, the maintenance procedures on pages 9 and 10 should be followed.

Operation Operating the valve is an important part of routine maintenance. Operation of the valve will help to break-up any buildup on the seat face and/or ball and, if so equipped, will rotate the seat rings 15o , distributing the wear on the insert.

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Double Block and Bleed Whether in the open or closed position, pressure on each side of the ball is blocked from the body cavity by the seat ring. The body cavity can then be blown down or drained through the body port. Take the following steps when block and bleeding a valve: Warning: Make sure proper safety garments are worn, and follow all customer safety procedures. Failure to do so could injure you or others.

Figure 10 - Valve closed.

Figure 11 - Valve open.

1. The Cameron bleed fittings have one or two exhaust ports. You should be aware of their orientation. Any debris in the valve or fitting will be exhausted at a high velocity. 2. If necessary, tighten the fitting to reorient the exhaust ports. 3. With the valve fully open or fully closed, open the bleed fitting all the way. When opening the bleed fitting, a backup wrench may be used to prevent accidental removal of bleed fitting. Figure 12 - Typical bleed fitting.

The process of block and bleeding the valve is intended to test the valve integrity. If the valve does not blow down, this indicates that the seats are leaking. Consult the Troubleshooting section. Warning: Never try to block and bleed the valve in the partially open position. Failure to do so could injure you or others.

Figure 13 - Cameron T31 seat section.

Seat Cleaning

Gear Maintenance

The seat pocket area is the primary area where any valve can be affected by contaminants in the lines. To insure the seat's free movement, it is recommended that the valve seat pockets be cleaned routinely with an approved product. (The frequency of routine cleaning depends on the severity of service, but once a year is a good guideline. Contact your Cooper Cameron Valves Representative for assistance.) Cleaning procedures can be found on page 13.

The following gear maintenance should be performed along with the valve maintenance:

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1. Inspect housing for damage and wear. 2. Inspect weather seal and replace, if damaged. This will prevent water from entering the gearbox and causing corrosion. 3. Lubricate gear, using an approved lubricant.

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Troubleshooting Trouble

Probable Cause

Remedy Operate the valve to the fully closed position.

The valve is not closed completely.

Block and bleed the valve to insure that the leakage has stopped. Refer to Block and Bleed procedure on page 10. Properly adjust the operator stops. Refer to Setting Stops on page 7.

The seats are leaking. Operator stops are incorrectly adjusted.

Block and bleed the valve to insure that the leakage has stopped. Refer to the Block and Bleed procedure on page 10.

The seat rings are malfunctioning.

Clean and flush the seat rings. Refer to the Injection Procedure section on pages 13 - 15.

Stem screw or nut is loose.

Tighten the stem screw or nut tightly enough to stop the leak. Do not exceed torque value for stem screw. Contact your Cooper Cameron Valves Representative to obtain torque values. Operate the valve to make sure the stem is causing the leak.

The stem is leaking.

Replace stem seal. Contact your Cooper Cameron Valves Representative for assistance. The stem seal is damaged.

Inject a small amount of sealant into the stem injection fitting.

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Troubleshooting (cont.) Trouble

The valve is difficult to operate.

Probable Cause

Remedy

The operator is malfunctioning. (Worm gear operators only)

Perform gear maintenance outlined on page 10.

There is a build up in the seat area due to line contaminates.

Clean the seat area as outlined on page 10.

Loosen the stem screw or nut. Stem cap screw or nut is too tight.

Trash in fitting. Sealant fitting is leaking. Fitting seal is damaged.

Fitting leaks between coupler and button head.

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Operate the valve. Tighten the stem screws or nut to the appropriate torque value. Contact your Cooper Cameron Valves Representative to obtain torque values. Inject a small amount of cleaner into fitting to dislodge trash. Install an auxillary fitting. Replace fitting when line is depressurized.

Paint or trash is on the surface of the button head fitting.

Clean surface of button head fitting.

Coupler seal is damaged.

Replace seal as per manufacturer's instructions.

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Injection Procedures Routine Cleaning Steps

Procedure

1. Inspect valve.

Inspect: Seat injection fittings. Stem injection fitting. (Do not inject into this fitting.) Body / bleed fitting

2. Inspect equipment.

Make sure the grease gun / pump is in working order and loaded with the appropriate product.

3. Inject standard valve flush.

Inject full seat capacity into each seat utilizing the seat injection ports. (Refer to capacity chart on page 16.) If this is the first time maintenance has been performed, and the valve has been in service over two years, perform Valve Cleaning procedures on page 14.

4. Operate valve. 5. Inspect valve.

Make sure it is safe to operate the valve. Fully operate valve three times. Make sure the valve is in the correct position. Clean the grease fittings. Replace fitting caps.

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Valve Cleaning Steps

Procedure

1. Inspect valve.

Inspect: Seat injection fittings. Stem injection fitting. (Do not inject into this fitting) Body bleed fitting.

2. Inspect equipment.

Make sure the grease gun / pump is in working order and loaded with the appropriate product.

3. Inject flush.

Inject full seat capacity into each seat, utilizing seat injection ports. (Refer to capacity chart on page 16.)

4. Operate valve.

Make sure it is it safe to operate the valve. Fully operate the valve three times.

5. Inject cleaner / flush.

Inject full seat capacity into each seat, utilizing seat injection ports. (Refer to capacity chart on page 16.)

6. Allow valve to soak.

Wait one to six hours to allow cleaner to penetrate the buildup and contaminates.

7. Inject flush.

Inject full seat capacity into each seat, utilizing seat injection ports. (Refer to capacity chart on page 16.)

8. Operate valve.

Fully operate the valve three times.

9. Test valve.

Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) If the valve will not bleed down, follow the sealant injection procedure on page 15.

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Sealant Injection Steps

Procedure Be sure to follow steps found within Troubleshooting section under Seats are Leaking on page 11 prior to proceeding.

1. Prior steps.

All nine steps found in Valve Cleaning on page 14 should be conducted prior to proceeding. 2. Verify valve postition.

Confirm valve is in the fully closed position. Use the Open and Closed View Ports (page 9) when available.

3. Inject standard sealant.

Inject full seat capacity into each seat, utilizing seat injection ports.

4. Test valve.

Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) If the valve will not bleed down, continue to the next step.

5. Operate valve.

Operate valve to the fully open position. Use the Open and Closed View Ports on page 9 to verify valve position.

6. Inject standard sealant.

Inject 1/2 seat capacity into each seat, utilizing seat injection ports. Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) If the valve will not bleed down, continue to the next step.

7. Test valve.

If the valve leaks in the closed but not in the open position: - The valve is not going fully closed. (use the Open and Closed View Ports on page 9 to verify valve position) - Possible ball damage. Contact your Cooper Cameron Valves Representative.

8. Operate valve.

Cycle valve open/close 6 times and return to fully closed position. Use the Open and Closed View Ports on page 9 to verify valve position.

9. Inject standard sealant.

Inject 1/2 seat capacity into each seat, utilizing seat injection ports.

10. Test valve.

Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) If the valve will not bleed down, continue to the next step.

11. Inject severe leak sealant.

Inject full seat capacity into each seat, utilizing seat injection ports.

12. Test valve.

Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) If the valve will not bleed down, continue to the next step.

13. Operate valve.

Cycle valve open/close 3 times and return to fully closed position.

14. Inject severe leak sealant. Inject 1/2 seat capacity into each seat, utilizing seat injection ports. Block and bleed valve. (Refer to Block and Bleed procedure on page 10.) 15. Test valve.

If the valve will not bleed down, continue to the next step

16. Contact your Cooper Cameron Valves Representative.

When Contacting your Cooper Cameron Valves Representative for assistance, please have the following information available: - Valve Size -Assembly Number - ANSI Class -Manufacture Date - Serial Number (Refer to nameplate on page 5) The Cooper Cameron Valves Representative may be able to provide additional information or schedule an on-site consultation.

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Injection Capacity Chart

Valve Size

Volume per Seat (oz)

Volume per Valve (oz)

Volume per Seat (cm3)

Volume per Valve (cm3)

2"

1

2

25

50

3"

1

2

35

65

4"

2

3

50

100

6"

2

4

65

130

8"

3

6

80

160

10"

3

6

90

180

12"

5

10

135

270

14"

5

10

155

310

16"

6

12

170

335

18"

9

18

265

525

20"

10

20

295

585

22"

11

22

330

655

24"

12

24

350

695

26"

13

26

395

785

28"

13

26

400

800

30"

15

30

445

890

34"

17

34

495

990

36"

21

42

620

1240

40"

32

64

960

1920

42"

34

68

995

1990

Extended Sealent Lines Capacity Chart

Nominal Line Size 1/4" 1/2"

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(6mm) (12mm)

Oustide Diameter of Pipe .540" .840"

(13.7mm) (21.3mm)

Volume of Sealant per Length of Pipe oz/ft .5 1.6

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

cm3/m 46 150

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Approved Flush / Sealant The following products are recommended by the cleaner / sealant manufacturers for the indicated service and condition. Contact your Cooper Cameron Valves Representative for availability through Cooper Cameron Valves. Product

Natural Gas

Sour Gas

Service Conditions

Crude Oil

Cleaner / Sealant Manufacturer Lubchem Sealweld

Flush

Valve Flush

Valve Cleaner

Valve Saver

Standard Valve Lubricant

2000 Light Lube

EQ 80

Lubchem "50-400"

Standard Sealant

80 bulk / 80-H stick

Total Lube 911

Everlast No.1

Standard Low Temp

50 bulk / stick

Winterlub 7030

Everlast No.1 AG

Severe Leak Sealant

80+FTFE bulk / Stick

Sealweld #5050

Formasil RS

Flush

Valve Flush

Valve Cleaner

Valve Saver

Standard Valve Lubricant

2000 Light Lube

EQ 80

Lubchem "50-400"

Standard Sealant

65 bulk / stick

Total Lube 911

Lubchem "50-400"

Standard Low Temp

65 bulk / stick

Winterlub 7030

Lubchem "50-300"

Severe Leak Sealant

80+FTFE bulk / Stick

Sealweld #5050

Formasil RS

Flush

Valve Flush

Valve Cleaner

Valve Saver

2000 Light Lube

Sealweld Silicone Lubricant

Everlast WR

Standard Sealant

302 bulk / stick

Sealweld Silicone Lubricant

Everlast WR

Standard Low Temp

65 bulk / stick

Sealweld Silicone Lubricant

Everlast WR

Severe Leak Sealant

80+FTFE bulk / Stick

Sealweld Silicone Sealant

Formasil CO2

Flush

Valve Flush

Valve Cleaner

Valve Saver

Standard Valve Lubricant

2000 Light Lube

EQ 80

Lubchem "50-400"

Standard Sealant

80 bulk / 80-H stick

Total Lube 911

Lubchem "50-400"

Standard Low Temp

50 bulk / stick

Winterlub 7030

Lubchem "50-300"

Severe Leak Sealant

80+FTFE bulk / Stick

Sealweld #5050

Formasil WR

Standard Valve Lubricant Dry CO2

Val-Tex

Valve Cleaner / Sealant Manufacturers Val - Tex Valves Incorporated of Texas 10600 Fallstone Rd. Houston, TX 77099 281/530-4848 800/627-9771

Sealweld 7240 Brittmore Suite 120 Houston, TX 77041 713/937-9222 800/237-0564

Lubchem Inc. P.O. Box 2626 Spring, TX 77383 281/350-9600

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Stem Designs 1", 1.5" and 2" Stem Design 1

ITEM 1 2 3 4 5

2

DESCRIPTION Cap screw Disc spring Stop nut Stem seal washer Stem seal

3 4 5

Figure 14 - 1", 1 1/2", and 2" stem design.

3" Stem Design

1 2 3

ITEM 1 2 3 4 5 6

DESCRIPTION Nut Disc spring Keyed shaft Stud Stem seal washer Stem seal

4

5 6

Figure 15 - 3" stem design.

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1 2

4" and Larger Stem Design

ITEM 1 2 3 4 5 6

3

4

DESCRIPTION Nut Disc spring Keyed shaft Stud Stem seal gland Stem seal

5 6

Figure 16 - 4" and larger stem design.

Notes

Cameron Type 31 Welded Body Ball Valve Installation, Operation and Maintenance Manual

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Headquarters Cooper Cameron Valves 16500 South Main Street, Missouri City, TX 77489-1300 Phone: 281-499-8511, 800-323-9160, Fax: 281-499-6965 USA Cooper Cameron Valves No. 6 Holloway Blvd., Ville Platte, LA 70586-9788 Phone: 318-363-7500, Fax: 318-363-7516 France Cameron France, S.A. Plaine Sainte-Pierre, CS 620, 34353 Beziers Cedex, Beziers, France Phone: 011-33-67-111500, Fax: 011-33-67-111600

http://www.ccvalve.com

c Cooper Cameron Corporation, Cooper Cameron Valves Division, Printed in USA / 8-99/TC1411-A