Schlumberger CAMERON AOP D2 Series User manual

Valves &
Measurement
DRAWN BY : E Keerthika DATE: 16-Sep-2020 REVISION
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Schlumberger-Private
AOP Series D2 Trunnion Ball Valve 6” FP-12” RP/FP
Installation, Operation, and Maintenance Manual

Valves &
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TABLE OF CONTENTS
BILL OF MATERIAL 6” to 12” FP & RP class 150 to 600 .................................................................................................. 4
PARTS LISTING FOR PLASTIC INSERT SEATED VALVE – SEE FIG. 1 .............................................................................. 5
SCOPE ............................................................................................................................................................................ 6
STORAGE ........................................................................................................................................................................ 6
INSTALLATION AND OPERTAION INSTRUCTIONS .......................................................................................................... 6
BEFROE INSTALLATION SAFETY INFORMATION ......................................................................................................... 6
INSTALLATION ........................................................................................................................................................... 7
FIELD TESTING ........................................................................................................................................................... 8
OPERATION ................................................................................................................................................................ 9
MAINTENACNE PROCEDURES ........................................................................................................................................ 9
DRAINAGE PROCEDURE ............................................................................................................................................. 9
LUBRICATION- GREASE INJECTION .......................................................................................................................... 10
VALVE RECONDITIONING ............................................................................................................................................. 12
DISASSEMBLY ............................................................................................................................................................... 13
CLEANING ................................................................................................................................................................ 14
INSPECTION ................................................................................................................................................................. 14
REASSEMBLY ................................................................................................................................................................ 15
BARE STEM VALVES-6” TO 12” (FP & RP) CLASS 150 TO 600 ................................................................................. 15
GEAR OPERATor assembly ........................................................................................................................................... 20
TROUBLESHOOTING .................................................................................................................................................... 23
CONTACT INFORMATION ............................................................................................................................................ 24

Valves &
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All the information contained in this manual is the exclusive property of Cameron. Any reproduction or use of the
calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden without the
written permission of Cameron or its authorized agent.
The procedures included in this book are to be performed in conjunction with the requirements and recommendations
outlined in API Specifications. Any repairs to the equipment covered by this book should be done by an authorized
Cameron service representative. Cameron will not be responsible for loss or expense resulting from any failure of
equipment or any damage to any property or death or injury to any person resulting in whole or in part from repairs
performed by other than authorized Cameron personnel. Such unauthorized repairs shall also serve to terminate any
contractual or other warranty, if any, on the equipment and may also result in equipment no longer meeting applicable
requirements.
File copies of this manual are maintained. Revisions and/or additions will be made as deemed necessary by Cameron. The
drawings in this book are not drawn to scale, but the dimensions shown are accurate.

Valves &
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BILL OF MATERIAL 6” TO 12” FP & RP CLASS 150 TO 600
Figure 1 – D2 Series Standard Seat (6” to 12” FP & RP class 150-600) Bare Stem
Figure 2
–
D2 Series Standard Seat (
6” to 12” FP & RP
class 150
-
600) Bare
Stem

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PARTS LISTING FOR PLASTIC INSERT SEATED VALVE – SEE FIG. 1
Item Description Qty
1 BODY 1
2 TAILPIECE 1
3 BALL 1
4 STEM 1
5 BEARING RETAINER 2
6 BEARING 2
7 BEARING RETAINER PIN 4
8 SEAT RING WITH PLASTIC INSERT 2
11 O-RING, SEAT RING 2
12 O-RING, SEAT RING 2
13 BONNET 1
14 ADAPTER PLATE 1
15 BODY STUDS *
16 BODY HEX NUTS *
17 CAP-SCREW BONNET *
18 CAP-SCREW ADAPTER PLATE *
19 O-RING, TAILPIECE 1
20 O-RING, STEM 2
21 O-RING, BONNET 1
24 BUSHING GLAND 1
25 CYLINDRICAL SPRING *
26 UPPER THRUST WASHER 1
27 BALL THRUST WASHER 2
28 DRIVE PIN 4
29 KEY 1
30 TORQUE PIN 2
32 BODY VENT PLUG 1
34 GREASE FITTING 2
35 CHECK VALVE 2
36 BLEED PLUG 1
39 VENT PLUG 1
41 NAMEPLATE (Not shown) 1
42 DRIVE SCREW (Not shown) 4
Table 1 – D2 Series Standard Seat (6” to 12” FP & RP class 150-600) Bare stem Parts List
* Quantities depending on size and class

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SCOPE
AOP D2 series ball valves 6” to 12”, FP & RP are full bore, through conduit, bi-directional, anti-blowout stem,
double block and bleed with trunnion mounted ball for easy operation.
These valves are equipped with plastic seat made of Nylon insert; all the seats are self-relieve type seats to
eliminate cavity pressure lock. All valves have a built-in sealant injection system for emergency seat seal and a
stem sealant fitting for stem seal recovery. The trunnion ball valve uses metal- backed self-lubricating bearings and
thrust washers to reduce torque. The stem is separated from the ball to eliminate side loads.
The handwheel can be removed from the gear shaft by taking out the split pin or screw
STORAGE
After the valves have been assembled and tested, the valves are drained and painted. Sealing surfaces of
connection flanges are greased and covered by protectors. All valves are delivered in fully open position, unless is
actuated with a normal close position actuator. If the valve is lever operated, the lever may be separately
packaged for easier handling and transportation. If the valve has a gear operator, the gear is installed on the valve
and factory adjusted for open and closed position.
The gear handwheel may be separately packaged for easier handling and transportation. All D2 valves should be
stored in fully open position as received, with the flange seal surfaces and the bore greased, and the protectors
installed on the flanges.
INSTALLATION AND OPERTAION INSTRUCTIONS
BEFROE INSTALLATION SAFETY INFORMATION
Valves shall be operated and maintained strictly in accordance with these procedures. Operation or maintenance
outside of 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.
Before any work is performed on a valve, personnel working on the valve must obtain the proper work permits
required by his employer. Personnel shall always use safety precautions set forth by the law and regulations
required by his employer. Personnel shall also be aware that any venting or draining of fluids from the valve shall
be done in accordance with safety and environmental procedures in force at the location.

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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 intended purpose. Any safety or protection devices on the valve shall
not be permanently removed or altered unless written approval is received from Cameron representative.
Transport, unpacking, lifting, connections to the different types of systems (electric, pneumatic, hydraulic systems,
etc.) shall be made by expert and qualified personnel.
Should any difficulties or abnormalities arise which cannot be solved by the technician, contact a Cameron
representative.
Any servicing not covered by these instructions must be made by an authorized service center, after preliminary
approval has been given by Cameron representative.
INSTALLATION
Before installation, ensure the grease fittings and sealing surfaces of connection flanges are not damaged during
transportation. Remove the connection flange protectors and ensure that no foreign materials are inside the valve
bore. If pressure tests are conducted before installation, drain the valve to remove testing water.
Clearly identify the valve through its data plate, check its weight with the packing list or relevant documents and
then place it on a horizontal surface, using suitable handling equipment. Handling equipment must be provided
which is appropriate for the total weight of the package.
Use the lifting eyes on valve body to lift the valve. Do not use lifting lugs or eyes provided on the gear or actuator,
if present. Pay attention that slings do not damage the gear or actuator. Lift the valve and put it on a plane,
horizontal surface, take care to avoid damaging the valve connections by using wooden saddles or other suitable
equipment.
To avoid the ingress of debris or sand into the ball and seat area the protective covers should not be removed until
the valve is ready to be installed in the line. When the valve needs to be installed in the line take away the
protective plastic or wooden flange protectors.
During installation the valve must be fully open and the line sections, between which the valve will be installed,
must be aligned, clean and correctly spaced. Should the valve be closed, the exposed face of the ball must be
protected with grease or other anti-adhesive product.
When the valve has butt welding ends, welding on the line must be performed using the proper welding
procedure. After welding, clean and check the weld bead and repair as required.

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AOP D2 valves may be installed in any position with either end facing upstream. The valve should be installed in
such a way as to facilitate maintenance, easy access to the valve fittings and actuating operations.
When installing the valve allow for possible deformations caused by the expansion of the line. The valve must not
support the line. Avoid any strain in the valve body.
CAUTION: Do not overload the valve beyond the design piping loads stated on the requirements.
Use studs, nuts and raised face gaskets or ring joints, as per size and class conforming to ASME B16.5. Tighten the
studs alternately, cross pattern method, several times, using the torques recommended by ANSI or gasket
manufacturer specification.
CAUTION: While all AOP D2 trunnion ball valves have self-relieving seats as standard equipment, it is
recommended that appropriate safeguards be put into place to prevent exceeding the pressure/temperature
limits given by the manufacturer.
FIELD TESTING
When field testing is required the following procedures are recommended:
1. Ensure that the test fluids are compatible with the valve seat and seal material.
2. Flush the system to remove foreign material that may be in the line as a result from installation
procedures, to avoid damages to the ball and seats.
3. If performing line shell testing, the valve shall be in half open position. The maximum line pressure can be
1-1/2 times the valve maximum cold working pressure.
4. If performing seat testing, make sure the valve is fully closed. The maximum pressure for seat testing is
the maximum cold working pressure.
5. After completion of testing, purge all test fluids from the valve.
CAUTION: If the seats are tested to a higher pressure than maximum cold working pressure, the seats can be
permanently damaged. If a higher test pressure is desired contact Cameron representative for details.

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OPERATION
AOP D2 series ball valves only work in the fully closed or fully open position; these valves work for on/off service
only.
WARNING: These valves shall never be operated partially open or partially closed. Throttling (partial opening) or
“pinching” flow may cause non-uniform wear on seats and ball over the sealing surfaces where it is exposed to
the flow line, preventing tight shut-off.
To close the valve, turn the lever or gear handwheel clockwise until it stops; to open the valve turn the lever or
gear handwheel counterclockwise until it stops.
All lever operated valves should have the lever in line with valve through bore when opened and perpendicular (90
degrees) with the through bore when closed.
All gear operated valves have the gear indicator aligned with valve through bore when opened and perpendicular
with the through bore when closed. The gear has also “OPEN” and “SHUT” markings.
While opening or closing the ball must reseat, this reseating torque is higher than the run torque. If lever operated
turn the lever until the stop plate stops on the stop screw. If gear operated turn the handwheel until the gear has a
positive stop. If the valve is motor actuated read carefully the actuator operation manual.
CAUTION: The end stops have shop set to assure the correct 90 deg. rotation from fully open to fully closed
position. Do not change their adjustment. If the valve is not correctly reseated at the end of opening or closing,
the ball and the seats can quickly be damaged when exposed to flow pressure, preventing tight shut-off.
These valves can be operated by one person. It is recommended that no extensions be used for operating the
valve.
MAINTENACNE PROCEDURES
The D2 series ball valves have a tight seat to ball seal insuring leak-free performance for a long period of time.
However, all valves can be drained and lubed depend on application conditions or anytime if desired. Also, the
gears are factory lubricated for long operation (on gear operated valves). If desired the gear can be lubricated
using the lube fitting located on the side of the gear operator.
DRAINAGE PROCEDURE
Valves may accumulate water, scale, deposits and other foreign matter, during their service. These materials may
damage the valve in the following ways:
1. At low temperature, ice may form inside the valve hindering its normal operation.

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2. Foreign matters may prevent the valve from fully closing and the ensuing throttling may damage the ball
or the seat seals. Foreign matter may get caught between the ball and the seat and damage their
surfaces.
A drainage schedule is the best way to prevent damage caused by foreign matter. However, it is recommended
that drainage should be carried out in the following cases:
1. Whenever the valve does not close
2. Before the arrival of the cold season
3. After washing the line
4. After hydraulic test
For a drainage procedure, follow the below instructions:
1. Close the valve completely.
2. Slowly open the drain fitting (35) located on the body lowest point; the vent fitting (36) located on the
body for higher point.
CAUTION: Open the drain valve slowly until the pressure in the body cavity has been discharged. Make sure the
fitting body does not unscrew when untightening the fitting stem. If necessary, use a backup wrench to prevent
the fitting body from unscrewing.
LUBRICATION- GREASE INJECTION
The D2 series valves have been designed and tested in such a way that they do not require the use of lubricating or
sealing grease during their normal service operation.
However, should the need arise, the D2 series ball valve 150 to 600 class is equipped with grease injection fitting
for each seat.– see table 2 for recommended lubricants.
This may be necessary in the event of slightly damage to the seats caused by debris in the line; before operating
the valve if the valve has been left in its position, either fully open or fully close, for long period of time; as soon as
an increase of stem torque is noticed.
CAUTION: Grease fittings should not be removed if there is pressure in line. Grease fittings should never be
painted.