ghdp_spring return_manual
Contents
1. S pg 10 1 Setting of angular stroke pg 12 1 Arrangement for start up 2 Start up MAIN TENANCE i pg 14 1 General 2 Off line periodic testing 3 On line periodic testing 4 Extraordinary maintenance WARNING 5 MS pg 18 TROUBLESHOOTIN Gisscsssissasassasssasnassnseiasassonaisiisessescoistousessisenenatossundusaissonseseanssosshsisessssssiuesaanvaians pg 19 DRAWINGS TT M pg 21 1 Exploded drawing and parts list F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com Page 2 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid USE AND STORAGE OF THIS MANUAL The user manual has to be considered as an integral part of the pressure equipment supplied and must be kept until final disposal of the equipment The manual must be always available for consulting near where the equipment is located and conserved in dry dust free environment In case o2. Attention the customer must take precautions to prevent the actuator chamber unmanned does not aspire from the outside air not filtered moisture water or other substances harmful for the actuator 10 If possible operate the actuator in order to check that it actuates smoothly the valve Before this operation verify that supply fluid composition filtration and hydration correspond to the ranges for which the actuator was designed In case of doubts please see the Motive Energy section on this manual or contact Actuatech technical department ru uc Puce puso acc p EP GM ueque scq 2 H n n ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 P 80 f23 http www actuatech com e mail actuatechGactuatech com ages o COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid Direct assembling Assembling by interposing an adapter and a coupling joint In case of use of an adapter for the connection of the valve using the connection with the socket closed 50 as to ensure a complete protection of the moving parts joint see image below
3. Paper 16 17 AloyStee O 18 19 Grub Screw 20 Accessories Bracket AllySteel _ AloyStee O 22 O 23 CLOSDiob AloyStee 24 AloyStee 25 Dotalabe AloyStee O 7_ Bras 28 InnerSideCap Carbon Steel 29 RodBushing SteebBronze PTFE 30 CenteingRng Alloy Steel 31 1 32 PistonRod AloyStee e 33 PlateRodSed AlloySteel 34 Carbonsieel 36 washer O Alloy Steet O SidngRng 40 Carbon Steel 41 OvuterSideCop Carbon Steel 42 TeRod 44 lftngRng Carbon Steel 45 Screw 46 47 1 48 Seat Polyurethane 4 PaperSeal Poper 50 ReductionRng AloyStee 51 Stop SettingScrew _ 52 SedingWasher AloySteel NBR 53 Stop Nut O 54 StopBotCover AloyStee 55 56 SpingCap CaroonStee 57 Spring CenteringRing Alloy Steel 57 2 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 22 of 23 http www actuatech com e mail actuatech actuat
4. Closed Connector ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatechGactuatech com 8 1148 Page 9 of 23 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid SETTING 1 SETTING OF ANGULAR STROKE A SPRING RETURN PNEUMATIC ACTUATOR WITHOUT MANUAL OVERRIDE A 1 SETTING OF THE POSITION CLOSED VALVE on standard N C actuator The setting of the closed valve position is performed by adjusting the screw which is inserted into the end flange of the pneumatic cylinder as follows 1 Apply low pressure to outboard side of cylinder to remove load from stop bolt 1 2 Remove the stop bolt cover 2 the sealing washer 3 and loosen the stop nut 4 with sealing washer 6 3 Screw the stop setting screw 5 to reduce the actuator angular stroke or unscrew the stop setting screw 5 to increase the actuator angular stroke 4 Tighten the stop nut 4 ensuring sealing washer 6 is properly centred on the stop setting screw and fitted in the machined recess in the flange Operate the actuator in open valve position apply pressure to outboard side of cylinder Operate the actu
5. Setting section Carry out a few operations with the actuator in order to check that the movement is regular and that there are no leakages through the seals Attention See page 8 for the recommended tightening torques ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com 8 1148 Page 16 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid LUBRICATION Usually it is not necessary to lubricate the actuator because its mechanism is lubricated for life The following greases are used by Actuatech S p A to lubricate the mechanical components and are recommended for future lubrication all the greases are silicon free PISTON CYLINDER lubrication MANUFACTURER TECNOLUBE SEAL TRADE NAME SYNTHY POLYMER 402 COLOR BLUE OIL TYPE SYNTHETIC SCOTCH YOKE MECHANISM HOUSING GUIDE BAR lubrication MANUFACTURER MOLYKOTE TRADE NAME P1500 COLOR WHITE OIL TYPE SEMI SYNTHETIC NOTE The above described greases types are for lubrication of scotch yoke standard actuators 20 C 80 ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel
6. 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com 8 1148 Page 17 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid WARNINGS It is the responsibility of the user to ensure that the following conditions are respected 1 10 11 12 13 The pressure in the cylinder must not exceed the range indicated on the actuator s nameplate The pneumatic supply line must take in account the necessary precautions in order to respect the required conditions Use appropriate systems to avoid the risk of overpressure The air cylinder exhaust must be piped in safe areas and put in positions not dangerous for the operators Check that the noise emitted from the exhaust of the cylinder respect current standards The temperature of the cylinder must not exceed the range indicated on the actuator s nameplate Important factors such as the temperature of the valve and pipeline as well as of the local environment and sun exposition will affect the actuator temperature and should be considered Ensure that environmental conditions are compatible with design presumed conditions In case of doubts please contact Actuatech technical department Verify that supp
7. 8908143 Page 3 of 23 http www actuatech com e mail actuatech actuatech com COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid PRESENTATION 1 DESCRIPTION OF SPRING RETURN GHDP SERIES ACTUATORS The GHDP series actuators are pneumatic actuators specifically designed to guarantee efficiency and reliability in heavy duty services The main components of spring return version units are the following 1 1 Ascotch yoke mechanism which transforms the linear movement of the pneumatic cylinder into a rotary movement suitable to operate quarter turn valves such as ball valves butterfly valves or plug valves The scotch yoke mechanism is included into a perfectly sealed housing made of welded carbon steel which protects it against corrosion and that guarantees safety to the personnel during the operations It is also fitted with a guide bar suitable to support the transverse forces and to ensure the proper alignment of the piston rod and with sliding blocks and yoke bushings made of bronze suitable to reduce the friction and to guarantee a long working life In particular the guide bar is chromium plated in order to guarantee its protection against corrosion 1 2 The pneumatic cylinder made of carb
8. COMPANY WITH 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM h Yok CERTIFIED BY DNV Scotch e part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 1 0 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid INSTALLATION COMMISSIONING AND MAINTENANCE USER MANUAL GHDP SERIES SPRING RETURN PNEUMATIC ACTUATORS ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 10 23 http www actuatech com e mail actuatech actuatech com 8 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM Scotch Yoke part turn pneumatic uec ied ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid SUMMARY TABLE USE AND STORAGE OF THIS MANUAL 2 24 2 1 24240 4 404 1 00 0 1 0 pg 3 pg 3 PRESENTATION opisi asia pg 4 1 Description of the actuator STORAGE AND PRE INSTALLATION sesesesecsssesesecossesosocossososssoseososoesososososossosossesosossesesossses pg 5 1 Checks to be carried out at the receipt of the actuator 2 Storage 3 Instructions to assemble the actuator onto the valve Xp m
9. TIVE ENERGY The operating media should be dry and filtered compressed air not necessarily lubricated or inert gases compatible with internal actuator parts and lubricants The operating media shall have a dew point equal to 20 or to be at least 10 below the ambient temperature ISO 8573 1 Class 3 The maximum particle size shall not exceed 40 um 150 8573 1 Class 5 Check that the pressure is in not in excess to the maximum value as indicated on the nameplate ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com Page 12 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid 2 START UP During the start up of the actuator it is necessary to check that e The pressure of the process supply as well as its quality filtering degree dehydration are as prescribed e pressure in the cylinder do not exceed the range indicated on the actuator s nameplate e Use appropriate systems to avoid the risk of overpressure e The air cylinder exhaust is piped in safe areas and put in positions not dangerous for the operators e pneum
10. als and lubricate them with a grease film please consult Lubrication section Taking care not to damage the seals proceed with the reassembling as follows e Insert the stem of the piston into the head flange Add threadlocker and screw the stem in the guide block see page 7 for the recommended tightening torques Add threadlocker and screw the grub screw on the guide block to lock piston stem Reassemble the piston with the shoulder washer and O ring on the stem e Add threadlocker and screw the nut with relative washer see page 7 for the recommended tightening torques e Lubricate the flange gaskets and the piston seals and reassemble the cylinder tube and the bottom flange Add threadlocker and uniformly screw the nuts on the tie rods see page 7 for the recommended tightening torques e Lubricate the parts inside the central body please consult Lubrication section and reassemble the cover with his gasket and screw the central body screws Re make the setting of angular stroke see Setting section Carry out a few operations with the actuator in order to check that the movement is regular and that there are no leakages through the seals ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 Page 15 of 23 http www actuatech com e mail actuatech actuatech com 8 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV
11. atic connections do not show any leakage If necessary tighten the nuts of the pipe fittings e feed voltage values of the electric components solenoid valves coils micro switches pressure switches etc if applicable are as prescribed e The required remote signals such as valve position air pressure etc are correct e The actuator controls such as remote control local control emergency control etc if applicable are properly working The setting of the components of the actuator control unit is according to the requirements of the plant e The painted parts have not been damaged during the transport assembling or storage operations If it is necessary after having removed rust repair the damaged parts by following the applicable painting specifications ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com 8 1148 Page 13 of 23 COMPANY WITH 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid MAINTENANCE 1 GENERAL As a general rule based on our many years of experience in the field together with our customers know how Actuatech technical department has selected mat
12. ator in closed valve position remove pressure of the outboard side of cylinder Verify that the adjustment is correct otherwise repeat from the step 1 Reinstall the stop bolt cover 2 ensuring sealing washer 3 is properly centred on the stop setting screw and fitted in the machined recess in the stop bolt cover ON OM ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 10 23 http www actuatech com e mail actuatech actuatech com 190 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid A 2 SETTING OF THE POSITION VALVE on standard actuator The setting of the open valve position is performed by adjusting the screw which is screwed into the spring 1 2 3 Depressurize the cylinder to allow the spring to relax 1 Remove the spring stop cap 2 and the sealing washer 3 Screw the spring stop 4 to reduce the actuator angular stroke or unscrew the spring stop 4 to increase the actuator angular stroke Operate the actuator in closed valve position remove pressure of the outboard side of cylinder Operate the actuator in open va
13. cy Older data sheets are invalid STORAGE AND PRE INSTALLATION 1 CHECKS TO BE CARRIED OUT AT THE RECEIPT OF THE ACTUATOR ACTUATOR DATA PLATE The following information are mentioned on the actuator data plate Type Serial Number Order Number Allowable temperature range Supply pressure range Supply fluid Code Construction year Please check that the information marked on the data plate conforms with those specified on the order on the test certificate and on the delivery note DAMAGE DURING TRANSPORT On receipt of actuator check that it has not been damaged during the transport In case of damage of the paint work proceed to repair by following the applicable painting specification ACCESSORIES When the supply includes accessories please check that they are in conformity with those listed in the order and in the shipping documents SETTING OF MECHANICAL STOPS AND LIMIT SWITCHES In the event that the actuator has been delivered already assembled onto the valve the mechanical stops and electric limit switches if existing have already been set during the relevant assembling operations In the event that the actuator has been delivered separately from the valve the setting of the mechanical stops and electric limit switches if existing has to be checked and if necessary carried out after the assembling of the actuator onto the valve according to the instructions stated in this manual under the applicab
14. d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid REPLACEMENT OF ONLY THE DYNAMIC PISTON SEALS Usually it is not necessary to replace the piston seals but when for an out of ordinary use the piston seals must be replaced proceed as described here below Apply low pressure to outboard side of cylinder to remove load from stop bolt Remove the stop bolt cover the sealing washer and loosen the stop nut with sealing washer Unscrew the stop setting screw until it sticks out about 180mm from the flange Disconnect all pneumatic and electrical supply connections Make sure that there is no pressure in any part of the actuator Unscrew the nuts from the tie rods Remove the bottom flange Remove the cylinder tube Remove the O ring and the guide sliding ring from the piston Clean the piston gasket grooves and replace the O ring and the guide sliding ring Lubricate them with a grease film please consult Lubrication section Taking care not to damage the seals proceed with the reassembling as follows e Lubricate the flange gaskets and the piston seals and reassemble the cylinder tube and the bottom flange Add threadlocker and uniformly screw the nuts on the tie rods see page 7 for the recommended tightening torques Re make the setting of angular stroke see
15. d or limit switches not corteet See above Setting of angular stroke Disassemble cylinder components See above Extraordinary Maintenance Encrusted hardened lubricant remove the encrusted lubricant re lubricate See above STROKE NOT Lubrication and reassemble COMPLETED Check the valve manufacturer s documentation Disassemble cylinder components See Debris left in the cylinder during above Extraordinary Maintenance check extraordinary maintenance the presence of debris and if necessary remove them Reassemble Defective controls Exx RHR UERRBR ImM M M 10 ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 Page 19 of 23 http www actuatech com e mail actuatechGactuatech com COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid NOTICED FAULT POSSIBLE CAUSE SUGGESTED REMEDY Check supplied air pressure and if necessary correct and improve its regularity Disassemble cylinder Not regular pressure of process supply pressure components See above Extraordinary Maintenance remove the old lubr
16. data sheets are invalid 4 EXTRAORDINARY MAINTENANCE REPLACEMENT OF THE PISTON AND CYLINDER SEALS Usually it is not necessary to replace the piston and cylinder seals but when for an out of ordinary use the seals must be replaced proceed as described here below e Apply low pressure to outboard side of cylinder to remove load from stop bolt e Remove the stop bolt cover the sealing washer and loosen the stop nut with sealing washer e Unscrew the stop setting screw until it sticks out about 180mm from the flange Disconnect all pneumatic and electrical supply connections e Make sure that there is no pressure any part of the actuator e Unscrew the nuts from the tie rods e Remove the bottom flange e Remove the cylinder tube e Remove the O ring and the guide sliding ring from the piston e Unscrew the screws on the central body cover and remove the cover and the central body gasket e Holding the stem from the hexagon near the guide block unscrew the nut remove it with relative washer e Remove the piston together with the shoulder washer and O ring e Unscrew the grub screw that locks the stem of the piston in the guide block e Unscrew the stem of the piston from the guide block and remove it from the head flange e Remove the stem gasket and the relative O ring from the head flange e Remove the external O rings on both flanges e Carefully clean all the gasket grooves e Replace all the above mentioned se
17. ech com 8 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid dC Bronzer Spring Cartridge Stem Moyse 1 Carbon Steel a ENFIN ae S alesse Pp 45 E as 607 Bonded AloySteeFNER 1 68 pq 24 69 a ae F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 x Page 23 of 23 http www actuatech com e mail actuatech actuatech com
18. erials of construction and improved constructive principles that can specifically guarantee efficiency and reliability in heavy duty services for a long expected lifetime Actuatech actuators do not normally need any periodic maintenance However we recommend to follow regular testing and inspection schedule 2 OFF LINE PERIODIC TESTING Off line periodic testing activity is Proof Test PT Actuatech recommends performing Proof Test to verify the correct operation of the actuator Proof Test is a full 90 degrees stroke When the working conditions of the plant allow to do carry out some opening and closing operations with all the existing controls such as remote control local control emergency control and verify the actuator operates the valve correctly with the required operating time If some fault is noticed please consult troubleshooting table for resolution The recommended Proof Test interval TI is 1 Year 8760 h and it allows detecting torque decrease actuator blockage structural problems in scotch yoke and pneumatic cylinder components external leakage 3 ON LINE PERIODIC INSPECTION AND TESTING On line periodic testing activity is Visual Inspection VI and Partial Stroke Test PST Visual Inspection is an accurate external inspection of actuator Visual Inspection can reveal and prevent external corrosion external leakage and problems in scotch yoke and pneumatic cylinder external components Act
19. f loss of this manual the customer can require a copy of this specifying serial number actuator type date version and year of supply as indicated on the actuators name plate INTRODUCTION Read completely this manual before start any operation with or on the Actuatech GHDP series actuators This manual is produced to enable a competent user to install operate adjust inspect and maintain Actuatech GHDP Series actuator Users are responsible to follow the instructions in this manual as well as any additional documentation that has been supplied regarding the actuator or accessories supplied by Actuatech 5 Should further information or guidance relating to the safe use of GHDP range actuators be required it will be provided on request Users are also responsible to be familiar with and follow any relevant legislation or statutory provisions regarding health and safety It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to health and safety in the workplace It is extremely important that precautions are taken to avoid spark or static discharge in any areas of potentially explosive atmosphere All Actuatech actuators are tested prior to despatch F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 030
20. for accuracy Older data sheets are invalid TROUBLESHOOTING NOTICED FAULT POSSIBLE CAUSE SUGGESTED REMEDY Verify that the process supply pressure value is within the required range pressure of the actuator See actuator data plate Not adequate supply pressure Check regulator s filter If necessary substitute it Check the pipe work for leakage If Pipe work leakage necessary tighten the nuts of the pipe fittings Remove the fittings clean the ports and One OC both part Blocked reassemble the fittings Wrona fow control valve settings Adjust flow control valves settings to 5 55 increase supply flow Remove and clean silencers Exhaust port silencers blocked Check if during operations silencers are frozen adjust flow control valves settings to decrease supply flow APPARENT TORQUE DECREASE Check the controls status reset if necessary Check and refer to components manufacturer s supplied user manual Check the valve manufacturer s que documentation Check the required valve torque valve Wiornevalvesiaihs manufacturer s documentation and the provided actuator torque Actuatech documentation Internal Leakage Damaged Replacement of the piston seals see piston seals Extraordinary Maintenance above External Leakage Damaged Replacement of the cylinder seals see cylinder seals Extraordinary Maintenance above Setting of mechanical stops an
21. formed e Directly on the valve using the actuator housing flange with threaded holes Byinterposing an adapter and a coupling joint The standard assembly position of the actuator is made with cylinder axis parallel to the pipeline axis but must be in accordance with plant requirements perpendicular to the pipeline axis on request and with the valve model In order to assemble the actuator onto the valve proceed as follows 1 Checkthat the coupling dimensions of the valve flange and those of the valve stem meet the coupling dimensions of the actuator 2 Arrange the valve in the open or closed position according to the current position of the actuator The piston the spring and the scotch yoke of standard fail to close Spring Return GHDP actuators are mounted as shown below supplying the pressurized air in the external chamber the drive shaft rotates counter clockwise to open MMe 3 Clean the coupling flanges of the valve and of the actuator and remove whatever might prevent their perfect adherence Take care to remove oil and grease perfectly 4 Lubricate the valve stem with oil or grease in order to make the assembling easier 5 Liftthe actuator by connecting hooks chains or lifting belts to the supporting points of the actuat
22. icant re lubricate See above Lubrication and reassemble Check the valve manufacturer s Worn or sticked valve documentation W Consult Actuatech technical department for a components instructions IRREGULAR STROKE Not adequate lubrication MOVEMENT K F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 Page 20 of 23 http www actuatech com e mail actuatech actuatech com e ACTUATECH ACTUATOR TECHNOLOGY COMPANY WITH INSTRUCTION MANUAL MANAGEMENT SYSTEM Scotch Yoke part turn pneumatic 150 9001 GHDP Spring Return series ISO 14001 Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid DRAWINGS EXPLODED DRAWING AND PARTS LIST ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatechGactuatech com 8 1148 Page 21 of 23 COMPANY WITH 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic Re DoD im ACTUATECH GHDP Spring Return series SO 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid 1 5 1 6 AloyStee O Rod Bushing Steel Bronze PTFE Steel Pin Alloy Steel Sliding Block Bronze Seeger Alloy Steel O Ring NBR Screw Allo
23. le sections ACTUATECH S p A 8 1148 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 Page 5 of 23 http www actuatech com e mail actuatech actuatech com 20 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic 150 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid 2 STORAGE GENERAL INSTRUCTIONS The actuators leave the Actuatech S p A factory in excellent finish and working conditions which are guaranteed by the inspection certificate issued for each single actuator In order to keep the actuators in good conditions until they are assembled on the plant it is recommended to follow the rules listed here below during the storage period e Check that the plugs are properly assembled on the pneumatic and electric connections in order to avoid entry of foreign matters and water during transport and storage e The actuators which are not yet assembled onto the valves must be placed onto a wooden pallet in order to prevent any damage to the valve coupling flange LONG TERM STORAGE In the event of a long term storage the following rules are also recommended e Protect the coupling parts adapter and coupling joint flange etc with grease or protective oil Keep the actuators in a dry place or pr
24. lf or loss of performance 3 Fasten the piping in a right way in order not to cause loosening of threaded connections in the event that the system may be subject to strong vibrations 4 completion of the pneumatic connections operate the actuator in order to ensure that it works correctly Also check that there are not leakages in the pneumatic connections ELECTRIC CONNECTIONS The following instructions are applicable to actuators provided with electric accessories such as solenoid valves limit switches etc 1 Checkthat the components used for electrical connections such as cable hose conduits cable glands are in accordance with the requirements and codes applicable to the plant with reference to the mechanical and or explosion proof protection 2 The electric connection has to be carried out in order to avoid anomalous mechanical stresses in the cable entries both by using rigid conduits and trailing cables 3 Remove the plugs from cable entries 4 Connectthe electric feed control and signal lines to the actuator by linking them up with the terminal blocks of electric components in accordance with the applicable wiring diagram 5 Replace plastic plugs with metal plugs on the unused entries of the pull box in order to guarantee perfect seal and to comply with explosion proof protection codes where applicable 6 Checkthat controls and signals are properly working when connections have been completed MO
25. lve position apply pressure to outboard side of cylinder Verify that the adjustment is correct otherwise repeat from the step 1 Replace the sealing washer 3 and the spring stop cap 2 ensuring sealing washer 3 is properly centred on the spring stop cap 2 i ACTUATECH S p A 8 1148 Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com Page 11 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid START UP 1 ARRANGEMENT FOR START UP PNEUMATIC CONNECTIONS 1 Before connecting the actuator to the pneumatic supply line check that pipes and fittings are according to the applicable plant specifications in order to guarantee the required air flow for the operation of the actuator and to avoid that the supply pressure drops below the minimum allowable value 2 Clean the inside of the pipes used for connection by washing them with suitable detergent and by blowing air into them Take every precaution to remove any solid or liquid foreign matter from the pipe work to the actuator so as to avoid possible damages to the actuator itse
26. ly fluid composition filtration and hydration correspond to the ranges for which the actuator was designed In case of doubts please see the Motive Energy section on this manual or contact Actuatech technical department Don t use the cylinder for any other uses other than which it has been designed Follow regular maintenance schedule please consult Maintenance section Before doing any maintenance operation on the actuator it is imperative to ensure that no pressure remains inside the cylinder or other part of actuator The lifting points placed on the actuator are designed only for actuator lifting do not use these lifting points to lift actuator valve Actuatech S p A cannot be responsible for any damage to people animals or things due to an improper use of the product Actuatech S p A declines any responsibility for the products repaired by companies not authorised by Actuatech S p A Other extra warnings linked to the particular installation of the actuator must be taken into account by the installer ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com 8 1148 Page 18 of 23 Do INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV Scotch Yoke part turn pneumatic 150 9001 ACTUATECH GHDP Spring Return series SO 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee
27. on steel The cylinder tube is electrolysis nickel plated internally in order to reduce roughness of the surface to a minimum value and to provide highest protection against corrosion The relevant piston is made of carbon steel and is sealed by O rings and by a guide sliding ring in PTFE and graphite The dynamic seals of the cylinder are specifically designed to allow the use of the actuator without lubrication 1 3 Two mechanical stops to allow the adjustment of the valve angular stroke by means of the stop Screws which are screwed into end flange of the pneumatic cylinder and into the spring pack closing flange 1 4 Mechanical visual indicator of the position directly connected to the valve stem which shows the valve position during the entire actuator stroke 1 5 The spring pack is completely sealed and protected from the external environment If required the GHDP series of actuators may also be supplied complete with accessories such as positioner signalling switches position transmitter etc ACTUATECH S p A F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com 8 1148 Page 4 of 23 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accura
28. or If possible place the valve stem in the vertical position in order to make the assembling easier Ex M ACTUATECH S p A 11 F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 P Es f http www actuatech com e mail actuatech actuatech com 2867 0 9 INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid 6 Ifthe assembling operation is carried out by means of an adapter with a coupling joint supplied with the actuator as a separate part assemble it onto the valve stem before proceeding with the assembling of the actuator 7 Lowerthe actuator onto the valve so that the valve stem slips in the actuator yoke Fasten the actuator to the valve by means ofthe stud bolts which are screwed to its coupling flange 8 Tighten the nuts of the connecting stud bolts by following the recommended tightening torque listed here below RECOMMENDED TIGHTENING TORQUE 8 5 Nm 20Nm 40 Nm 70Nm 110 Nm 160 Nm 320 Nm 420 Nm 550 Nm 800 Nm 1100 Nm 1400 Nm 1700 Nm 9 Theactuator remote control functionality should be done respecting the air connection schema shown below
29. ovide some means of protection against the direct action of weather agents e If possible we also recommend operating periodically the actuators with filtered and dehydrated air Remember that after this operation all the threaded connections of the actuator and of the control panel must be carefully closed MOVIMENTATION e The actuator is normally supplied in boxes or on pallets that ensure the stability and protection against damage during movement e For handling the actuator use the appropriate lifting rings e Use belts or chains suitable to the weight of the actuator to be lifted Attention the lifting rings are designed to lift actuator only cf Lifting points are designed 1 for actuator only F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 http www actuatech com e mail actuatech actuatech com Page 6 of 23 COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM Scotch Yoke part turn pneumatic uec ied ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older data sheets are invalid 3 INSTRUCTION TO ASSEMBLE THE ACTUATOR ONTO THE VALVE The assembling of the actuator onto the valve can be per
30. uatech advises to perform Visual Inspection and to verify The signals to the control board are correct The process supply pressure value is within the required range The external components of the actuator are in good conditions The pneumatic connections do not show any leakage if necessary tighten the nuts of the pipe fittings The painting work of the actuator is not been damaged if necessary touch up damaged areas according to the applicable painting specifications The advised Visual Inspection interval Tlv is 6 months 4380 h and in any case it should be performed when Proof Tests and Partial Proof Tests are performed Partial Stroke Test can reveal and prevent the same functional failures than Proof Test If some fault is noticed please consult troubleshooting table for resolution The advised Partial Test interval Tles is 3 months 2190 h and it allows detecting torque decrease actuator blockage structural problems in scotch yoke and pneumatic cylinder components external leakage F lli Capponi 126 128 25068 Sarezzo BS ITALY Tel 39 0308908142 Fax 39 0308908143 m Page 14 of 23 http www actuatech com e mail actuatech actuatech com COMPANY WITH A INSTRUCTION MANUAL MANAGEMENT SYSTEM CERTIFIED BY DNV d Scotch Yoke part turn pneumatic ISO 9001 ACTUATECH GHDP Spring Return series 150 14001 ACTUATOR TECHNOLOGY Modification reserved Rev date 10 2014 No guarantee for accuracy Older
31. y Steel Steel Pin Alloy Steel Paper Seal Paper Indicator Alloy Steel Screw Alloy Steel O Ring NBR Grub Screw Alloy Steel Accessories Bracket Alloy Steel Screw Alloy Steel Screw Alloy Steel CLOSED Label Alloy Steel OPEN Label Alloy Steel Data Label Alloy Steel Rivet Alloy Steel Filter Brass Inner Side Cap Carbon Steel Rod Bushing Steel Bronze PTFE Centering Ring Alloy Steel O Ring NBR Piston Rod Alloy Steel Plate Rod Seal Alloy Steel O Ring NBR Piston Carbon Steel Washer Alloy Steel Alloy Steel NBR PTFE Graphite Carbon Steel Carbon Steel Alloy Steel Alloy Steel Carbon Steel Alloy Steel Brass NBR NBR Polyurethane Paper Alloy Steel Alloy Steel Alloy Steel NBR Alloy Steel Alloy Steel NBR Carbon Steel Alloy Steel Co O Ring Sliding Ring Cylinder Tube Outer Side Cap Tie Rod Liffing Ring Screw O Ring Cap O Ring Seal Paper Seal Reduction Ring Stop Setting Screw Sealing Washer Stop Nut Stop Bolt Cover O Ring Spring Cap Spring Centering Ring Cn E qe a a a a 8 Ool S m p pp l p po DEREN Ool go p qe a Pp E p s poo 2 8 RodBushing SteehBronze PIFE 9 steen 10 SidngBock Seeger AloySteel 12 1 12 Screw O 14 SfeePin O 15
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