DISTRIBUTED VALVES

AOP
Series D Trunnion 5000 WP Ball Valve

Installation, Operation and Maintenance Manual

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All the information contained in this manual is the exclusive property of Cameron. Any repro-
duction or use of the calculations, drawings, photographs, procedures or instructions, either
expressed or implied, is forbidden without the written permission of Cameron or its autho-
rized agent.

Initial Release 01
July 2012

© 2012 Cameron

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TABLE OF CONTENTS

AOPTM Series D Trunnion 5000 WP Ball Valve

Bill of Materials 2” to 4”.....................................................................................................4

Nameplate Information......................................................................................................5

Scope ....................................................................................................................................5

Storage.................................................................................................................................6

Installation...........................................................................................................................6

Operation.............................................................................................................................9

Routine Maintenance..........................................................................................................10

Draining Valve and Releasing Body Pressure....................................................................10

Low-Temperature Precautions...........................................................................................11

Maintaining Seals................................................................................................................12

Temporary Seal Restoration...............................................................................................12

Troubleshooting..................................................................................................................15

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BILL OF MATERIALS
2” to 4” x 4” 5000 WP

Figure 1 – AOP Series D Trunnion 5000 WP

Ball Valve

ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION

1. 1 Body 5 18. 1 Drain Fitting
2. 1 Tailpiece 19. 1 Tailpiece O-ring
3. 1 Lower Cover Plate 20. 1 Tailpiece Backup Ring
1 4. * Body Stud 21. 2 Stem O-ring
1 5. * Body Nut 22. 2 Stem Backup Ring
6. 6 Bolts (Lower Cover Plate) 23. 1 Trunnion O-ring
7. 1 Bearings (Stem) 24. 1 Trunnion Backup Ring
8. 1 Bearings (Trunnion) 25. 2 Seat O-ring
9. 1 Stop Plate 26. 2 Seat Backup Ring
2 10. * Retaining Ring 27. 2 Grease Seal Seat O-ring
3 11. 1 Stop 28. 1 Stem Seal
4 12. * Key (Square) 29. 1 Ball
13. 1 Nameplate 30. 1 Trunnion
14. 2 Drive Screw 31. 1 Stem
15. 2 Caution Tag 32. 2 Seat Assembly
16. 2 Grease Fitting 33. 2 Seat Wave Spring
17. 2 Hidden Check Valve 34. 1 Ground Wave Spring

1 Body Stud and Nut Qty.: 6 for 2”

8 for 3” to 4”
2 Retainer Ring: 3 for 2”
0 for 4”
2 for 3”
3 Stop: Socket Head Screw for 2” to 3”
Pin for 4”
4 Key, Square Qty.: 0 for 2” to 3”
1 for 4”
5 Drain Fitting: 2” through 4” = 1/2”
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NAMEPLATE INFORMATION
A nameplate is permanently affixed to each AOP Series D ball valve. The nameplate lists all the
information necessary to identify the valve when making inquiries. Attaching the nameplate
to the valve is the final step in a series of operations designed to provide you with quality
service when ordering replacement parts, accessories, or making any inquiry about your
valve’s operation or maintenance.

Figure 2 – AOP Series D Ball Valve Nameplate

ITEM STAMP
1. Size: Size is nominal bore size
2. Class: Pressure classification
3.* SN: Valve’s unique serial number
4. BM: Number of valve assembly bill of material
5. CWP: Cold working pressure; the working pressure of the valve in psi at 100° F (38° C)
6. Body: Body material
7. Temp.: Operating temperature range
8. Model: Valve’s model designations
9. Stem: Stem material
10. Ball: Ball material
11. Seat: Seat material
12. Seals: Seal material
13. DOM: Date of manufacture
14. MIT: Maximum impact temperature

* Most important data for obtaining replacement parts.

SCOPE
The AOP Series D end-entry, double block and bleed, trunnion ball valve is engineered for
lengthy reliable performance. Manufactured in a variety of body and seal materials, this valve
meets the requirements of the oil and gas pipeline industries and oil production industries, as
well as specialized pipeline and industrial process applications.

Available Sizes: 2”, 3”, and 4” 5000 WP

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STORAGE
After AOP Series D ball valves are assembled and tested, the valves are left in the fully 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 procedure
X-150771-01 and ensure adequate end connection covers are in place. Request a copy of
X-150771-01 from Cameron’s Valves & Measurement business segment.

INSTALLATION
AOP Series D ball valves can be installed in most positions with flow from either direction.
However, for best service life, there is a preferred horizontal position to increase sealing and
reduce the accumulation of sediment. In horizontal piping, it is preferred to have the stem
lying horizontal (i.e., stem toward the viewer) with pressure from the right. During operation,
flow will act as a siphon and will reduce retention of sediment. When handling or installing a
valve, keep the valve in the fully open position whenever possible to prevent foreign object
damage to the ball.
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 valve, gearbox or actuator
not designated for this purpose.
CAUTION

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.

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.
CAUTION

Flanged-end valves may be bolted into the line using two open or boxed end wrenches.
• Threads of flanged bolts and nuts should be lubricated to obtain proper loading of
bolts.
• Finger-tighten all nuts first.
• When tightening bolts, use the crisscross method and torque each bolt to ASME or
gasket manufacturer’s specification.

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HYDROSTATIC TESTING
When AOP Series D ball valves are installed in a piping system that requires hydrostatic testing
of the adjoining pipe, follow these procedures to reduce any damage that could occur to the
sealing surface and seat seals inside the valve.

Caution: Ensure that all test fluid contains corrosion inhibitors and that these are
! compatible with the valve seat and seal material.
CAUTION

1. The 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 should be placed in the partially open
position (approximately 10 degrees from the fully open position). This allows test
fluid into the body cavity of the valve.
3. The valve now is ready to be hydrostatic 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 (see Draining Valve and Releasing Body Pressure, page
13).
5. Close the valve body bleed fitting and return the valve to required operating
position, either fully open or fully closed.

Figure 3 – Correct Valve Lifting

Using End Connection Necks

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MOUNTING A GEAR/ACTUATOR
To mount a gear on a valve, use the following as guidelines.

Note: The following information is for typical gear designs. Specific instructions for each
design should be obtained from gear 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 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 and install it accordingly. A thin layer of anti-
seize or grease 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 position to match the mount-
ing flange.
4. It is now necessary to set the operator stops as outlined in the following section.

SETTING STOPS
AOP Series D ball valves do not have stops when mounting a gear or actuator. The stop plate
(item 9) and stop (item 11), are removed before mounting an operator. The 4” ball valve also
has no manual stop plate when specified for actuation. An adapter plate is provided.
1. Make sure that operating the valve to the fully open and fully closed positions will
not disrupt current operation of the line.
2. Loosen the open and closed stop screw locknuts on the operator.
3. Partially back out the stop screw on the open side of the operator.
4. Operate the valve to the fully open
position. This is indicated when the flats
on the stem are in line with the bore. If
the ball stops short of the fully open
position, additionally back out the open
stop screw on the operator and move the
ball to the fully open position.
5. Turn the open stop screw clockwise until
it stops, then tighten the locknut.
6. To set the closed stop, partially back out
the stop screw on the closed side of the
operator.

Figure 4 – Typical Gear Box with Stops

7. Operate the valve to the fully closed position. This is indicated when the flats on
the stem are perpendicular to the bore. If the ball stops short of the fully closed
position, additionally back out the closed stop screw and move the valve to the
fully closed position.
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8. Turn the closed stop screw clockwise until it stops, then tighten the locknut.
9. After mounting the operator, operate the valve three times to check for proper
movement.
10. Perform a seat seal test on each side of the valve.

OPERATION
AOP Series D ball valves operate from fully open to fully closed by a 90-degree turn of
the handle. The handle aligned with the pipe always means the valve is open. The handle
perpendicular to the pipe means the valve is closed. Additionally, for stems with keys, the bore
of the ball is in line with the key, and for stems with two flats and double-D configuration, the
bore of the ball is in line with the flats.
Worm gear operators, available on all size valves, have an arrow on the top of the operator
unit that indicates the “OPEN – CLOSE” position of the ball. The open and closed position of the
valve is set or controlled by stops on the worm gear unit. Facing the handwheel, rotating the
handwheel clockwise closes the valve while counter-clockwise opens the valve. The handwheel
should be turned until it contacts an open stop or closed stop, depending on the desired valve
position.

Note: Handwheel movement in these directions is an accepted industry practice for opening and
closing any valve with a worm gear operator.

AOP Series D ball valves can be power actuated. Pneumatic and hydraulic actuators, whether
of the fail-open, fail-close, or fail-last position type, have “OPEN – CLOSED” indicators on the
top of each unit On a pneumatic actuator, make sure filters and lubricators (if recommended
by the actuator manufacturer) are installed prior to the valve and actuator installation. Should
any maintenance be necessary, obtain the part number from the unit’s nameplate and contact
Cameron’s Valves & Measurement business segment or the nearest representative.
The body cavity of an AOP Series D ball valve can be blown down or drained through the body
vent port when the valve is closed with pressure on each side of the ball. Take the following
steps when double block and bleeding the valve.

Warning: Make sure proper safety garments are worn and follow all customer safety
procedures. Failure to do so could injure you or others.

1. Note the location of the body vent fitting. Check the direction of the hole on the
side of the vent fitting. Any debris in the valve or fitting will be exhausted at a high
velocity.

Warning: To avoid possibly being struck by liquid or foreign sold matter, position yourself so
the hole of the bleed fitting is pointing safely away from you and back up the vent
body so only the hex head on the top of the fitting is unscrewed.

2. With the valve fully closed, open the body vent fitting all the way. A backup wrench
on the body of the fitting should be used to prevent accidental loosening and removal
of the body vent fitting.
For additional information on venting, see Draining Valve and Releasing Body Pressure, page 13.
Warning: Never try to block and bleed the valve in the partially open position.

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ROUTINE MAINTENANCE
Under normal working conditions, the AOP Series D
ball valve is designed for lengthy, reliable service.
The following recommended practices and
procedures will ensure optimum
performance of your valve.

Caution: Verify compatibility of any sealant, lubricant

! or anti-freeze with the trim of the valve and
product in the line.
CAUTION

Types of Fittings: Figure 6 – Vent or Bleed Fitting

Figure 5 – Typical Injection Fitting

Figure 7 – Pressure Releasing Tool Shown on
Injection Fitting

DRAINING VALVE AND RELEASING BODY PRESSURE

After lengthy service, there is a possibility of water, line scale, sediment or other foreign mat-
ter collecting in the lower body cavity. It is advisable to periodically drain the valve to discour-
age development of conditions that can possibly lead to valve damage or impair the operation
of your valve. If draining is not regularly scheduled, it is strongly recommended to drain the
valve at these times:
• After hydrostatic testing
• After cleaning the line
• When valve cannot be fully opened or closed, foreign matter in the bottom of the
valve can not only prevent placing valve in a fully open or closed position, it also
can cause permanent damage to the internal sealing surfaces.
If the valve is equipped with a vent or bleed fitting in the lower drain, to release body
pressure or drain the valve, first place the ball in the closed position.

Warning: To avoid possibly being struck by liquid or foreign solid matter, position yourself so
relief port of vent or bleed (drain) fitting is pointing safely away from you and back
up the vent or bleed (drain) fitting so only the stinger is unscrewed.
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Carefully unscrew the stinger of the vent or bleed (drain) fitting to allow free flow of air,
liquid or foreign solid matter to escape from the body cavity. After body pressure is released
or valve is drained, screw the stinger of the vent or bleed (drain) fitting back in to close the
vent.
If the valve is equipped with a grease fitting in the lower drain, 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 the valve, first place the ball in the closed position.

Warning: To avoid possibly being struck by liquid or foreign solid matter, position yourself so
the outlet port of grease fitting is pointing safely away from you and back up the
grease fitting so only the safety cap is unscrewed.

Carefully remove the safety cap of the lower drain grease fitting. Back out the stinger of
the pressure releasing tool until it stops. Install the safety pressure-releasing tool onto the
uncapped grease fitting. Carefully screw the stinger of the releasing tool in (until the ball
check in the grease fitting is pushed off its seat). This will allow the valve to drain or release
body pressure. 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. Replace the safety cap on the lower drain grease fitting.

LOW-TEMPERATURE PRECAUTIONS
Prior to exposure to freezing temperatures, it is highly recommended that the valve be
drained. Water that can 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 antifreeze injected into the body cavity via the lower drain grease fitting
will prevent accumulated water from freezing.
It also is 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.

ROUTINE SEAT CLEANING

The seat pocket area is the primary area where any valve can be affected by contaminants
in the lines. To ensure 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. The following cleaning
procedure can be used on valves equipped with seat injection fittings:
1. Locate the seat injection fittings on the valve.
2. Make sure the grease gun/pump is in working order and loaded with the appropri-
ate product.

Warning: Back up the seat grease fitting 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 when the valve is under pressure.

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3. Remove the safety vent cap from each grease fitting. Attach the grease gun
connection onto the grease fitting and inject the full seat capacity of valve flush into
each seat.
4. Make sure it is safe to operate the valve. Fully operate the valve three times.
5. Remove the grease gun and replace the safety vent caps on the grease fittings.
If additional cleaning is desired, inject the full seat capacity of valve flush into each seat and
allow to soak for one to six hours. Inject the full capacity of valve flush again and operate the
valve (if safe to do so) three times. This additional cleaning may help break up buildup of con-
taminants.

MAINTAINING SEALS
The AOP Series D ball valve is non-lubricated. Unlike a typical plug valve, the AOP D-Series ball
valve does not depend upon the injection of sealant to activate seals. However, occasionally
injecting valve lubricant into seat and stem grease fittings will ensure optimum performance of
the seat and stem seals and can help maintain long reliable service.

TEMPORARY SEAL RESTORATION

If your valve seats or stem seal fail, normally it is possible to restore the seal or reduce any seat
or stem leakage for an extended period of time – until it is convenient to remove the valve
from service and replace the seals – with the injection of a sufficient amount of valve sealant
into the grease fitting (see chart for list of sealants). The valve must be equipped with the seat
and/or stem injection feature.
Temporary seat seal restoration with the valve under line pressure for valves equipped with seat
injection:
1. Fill the high-pressure grease gun with valve sealant.
2. Place the valve in a fully closed position.

Warning: Back up the seat grease fitting so only the safety cap will be removed from the fit-
ting. Carefully remove the safety cap from the seat grease fitting. NEVER remove the
grease fitting when the valve is under pressure.

3. Remove the safety vent cap from the grease fitting. Attach the grease gun
connection onto the grease fitting and inject sealant.
4. Repeat this process for the second seat grease fitting. If injection of the sealant is
difficult, flush the valve seats and attempt to inject sealant again. Replace safety caps
on the seat grease fittings.

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Temporary seat seal restoration with the valve out of line:

Note: Before removing the valve from the line, all pressure must be relieved from the valve
and line.

1. Fill the high-pressure grease gun with valve sealant.

2. Back up the seat grease fitting so only the cap will be removed from the fitting.
3. Carefully remove the safety cap from the seat grease fitting.
4. With the valve out of line, you should be able to view the bore interior.
5. Attach the high-pressure grease gun connection onto the grease fitting and inject
sealant until sealant enters the valve bore.
6. Repeat this process for the second seat grease fitting. Replace the safety caps on
the seat grease fittings.
7. Excess sealant should be removed from the valve bore before the valve is put back
in service.
Temporary stem seal restoration for valves equipped with stem injection fittings:
1. Fill the high-pressure grease gun with valve sealant.

Warning: Back up the stem grease fitting so only the safety cap will be removed from the
fitting.

2. Carefully remove the safety cap from the stem grease fitting.
3. Attach the grease gun connection onto the grease fitting and inject sealant into
the stem grease fitting.
4. Replace the safety cap on the stem grease fitting.

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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 Cameron’s Valves & Measurement business
segment representative for availability.

Service Cleaner/Sealant Manufacturer

Conditions Product Val-Tex Sealweld Lubchem
Flush Valve Flush Valve Cleaner Valve Saver
Standard Valve
2000 Light Lube EQ 80 Lubchem “50-400”
Lubricant
Natural Gas
Standard Sealant 80 bulk/80-Hs stick Total Lube 911 Everlast No. 1
Standard Low Temp. 50 bulk/stick Winterlub 7030 Everlast No. 1 AG
Severe Leak Sealant 80+ PTFE bulk/stick Sealweld #5050 Formasil RS
Flush Valve Flush Valve Cleaner Valve Saver
Standard Valve
2065 Light Lube EQ 80 Lubchem “50-400”
Lubricant
Sour Gas
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+ PTFE bulk/stick Sealweld #5050 Formasil RS
Flush Valve Flush Valve Cleaner Valve Saver
Standard Valve 2300 Silicone Light Sealweld Silicone
Everlast WR
Lubricant Lube Lubricant
Sealweld Silicone
Standard Sealant 302 bulk/stick Everlast WR
Dry CO2 Lubricant
Sealweld Silicone
Standard Low Temp. 65 bulk/stick Everlast WR
Lubricant
Sealweld Silicone
Severe Leak Sealant 80+ PTFE bulk/stick Formasil CO2
Sealant
Flush Valve Flush Valve Cleaner Valve Saver
Standard Valve
2000 Light Lube EQ80 Lubchem “50-400”
Lubricant
Crude Oil
Standard Sealant 80 bulk/80-Hs stick Total Lube 911 Lubchem “50-400”
Standard Low Temp. 50 bulk/stick Winterlub 7030 Lubchem “50-300”
Severe Leak Sealant 80+ PTFE bulk/stick Sealweld #5050 Formasil WR

Valve Cleaner/Sealant Manufacturers

Cameron’s Valves & Measurement Val-Tex Sealweld Lubchem Inc.
3250 Briarpark Drive, Suite 300 Valves Incorporated of Texas 7240 Brittmore, Suite 120 P.O. Box 2626
Houston, TX 77042 10600 Fallstone Road Houston, TX 77041 Spring, TX 77383
USA USA USA USA
Tel 1.281.499.8511 Houston, TX 77099 Tel 1.713.937.9222 Tel 1.281.350.9600
Toll 1.800.323.9160 Tel 1.281.530-4848 Toll 1.800.237.0564
www.c-a-m.com Toll 1.800.627.9771

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TROUBLESHOOTING

Trouble Probable Cause Remedy

Refer to actuator maintenance
manual or remove actuator cover and
Actuator unit
check stem adaptation and linkage
for damage
Lubricate seats with valve lubricant
Infrequent operation – lack of
and actuator with suitable industrial
lubrication
The valve is hard to operate grease
Apply heat or inject antifreeze
solution into valve, but consult with
Ice in valve operator
authorized dealer prior to using
remedy on operators
There is a buildup in the seat area Clean the seat area as outlined in
due to line contaminates Routine Seat Cleaning
Remove bore restrictions or check
Ball is not properly aligned with bores Restrictions in bore of valve or stop
stop in worm gear actuator and/or
of seats not set properly
actuator limit switches
Damaged actuator unit Replace broken or damaged parts
Restriction of pneumatic actuator
Remove restriction
vent
Erratic operation Faulty power supply Check power supply
Lubricate seats with valve lubricant
Infrequent operation – lack of
and actuator with suitable industrial
lubrication
grease
Valve is leaking between tailpiece
Damaged O-Ring seal Disassemble and replace O-rings
and body
Inject valve sealant into stem\fitting
Leakage around valve stem Damaged O-Ring seal
(if present) or replace stem O-ring
Apply heat or inject antifreeze
solution into body of valve; drain
Ice in body of valve
periodically to eliminate water
accumulation
Valve will not fully close Improper setting of actuator limit Reset actuator limit switches or stops
switches or stops in worm gear for proper closing
Lubricate seats with valve lubricant
Infrequent operation – lack of
and actuator with suitable industrial
lubrication
grease
Tighten safety cap or replace safety
cap if damaged
Damaged fitting
WARNING: Never remove entire
Grease fitting leaking grease fitting when valve is under
pressure.
Inject a small amount of cleaner into
Trash in fitting
fitting to dislodge trash

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TROUBLESHOOTING (Continued)

Trouble Probable Cause Remedy

Contamination around seat area due Clean the seat area as outlined in
to service Routine Seat Cleaning
Inject seat sealant for temporary seal
Damaged seat face or seat O-ring
or replace seats
Valve will not seal
Check that operator or limit switches
Valve not fully closed do not stop the rotation of ball prior
to reaching the fully closed position
Valve stops incorrectly set Adjust stops on actuator
Gear operator hard to operate or Drain water and lubricate if possible;
Water in gear
stuck replace weather seal if applicable
Low air flow Increase air flow and operation speed
Lubricate operator cylinder and seals
Dried operator seals
with approved lubricant
Pneumatic operators excessive chatter Restriction in vent Clear restriction
during operation
Actuator was undersized for service Check torque requirements of valve
conditions for service conditions
Service conditions require routine Refer to operator maintenance
maintenance and/or lubrication manual

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Notes:

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Valves & Measurement

3250 Briarpark Drive, Suite 300
Houston, TX 77042
USA
Toll 1.800.323.9160

For the most current contact and location information, visit: www.c-a-m.com

Copyright © 2012 Cameron, Printed in USA TC9210

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