Bettis Canada Ltd.
4112 91A Street
Edmonton, Alberta, Canada T6E 5V2
Tel: (780) 450-3600
Fax: (780) 450-1400
SERVICE MANUAL No. I-0021
LINEAR GAS / HYDRAULIC
GATE VALVE OPERATOR
Edmonton
CUSTOMER:
P.O.#:
W.O.#:
TAG:
DATE:
APPLIES TO OPERATOR MODEL:
I-0021--.WPD/1
REV5: NOV-23-98
SECTION I LINEAR GAS / HYDRAULIC GATE VALVE OPERATOR
DESCRIPTION DWG.NO PAGE
I SAFETY WARNINGS ..................................................... 4
DECALS, GAS / HYDRAULIC OPERATING PROCEDURES ....................... 5
II OPERATING INSTRUCTIONS .............................................. 6
III INSTALLATION .......................................................... 6
FIELD INSTALLATION LAYOUT.............................. I-0103 ......... 8
FIELD INSTALLATION LAYOUT.............................. I-0103-10 ...... 9
IV MECHANICAL STOP ADJUSTMENTS ........................................ 10
V PRESTART-UP CHECKS .................................................. 11
VI START-UP CHECKS ...................................................... 12
VII SCHEDULED MAINTENANCE AND TESTING .................................. 13
VIII LIMIT SWITCH INSTRUCTIONS ............................................. 15
IX END OF STROKE ADJUSTMENT INSTRUCTIONS .............................. 16
X LINEAR OPERATOR MAINTENANCE ........................................ 16
XI LINEAR OPERATOR DISASSEMBLY ......................................... 17
XII LINEAR OPERATOR ASSEMBLY............................................ 17
OPERATOR CUTAWAY ................................................... 19
XIII FLUID MAINTENANCE GUIDE .............................................. 20
XIV HYDRAULIC FLUID SPECIFICATIONS ....................................... 20
GAS / HYDRAULIC TANK FILLING............................ I-0021-12 ...... 21
XV OPERATOR REPAIR KITS ................................................. 22
XVI TROUBLESHOOTING..................................................... 23
XVII GENERAL SERVICE NOTES ............................................... 24
GAS / HYDRAULIC OPERATOR BASIC SCHEMATIC ............. I-0021-02 ...... 26
BASIC MANIFOLD ASSEMBLY ............................... A-0197 ........ 27
RELAY A324-M ........................................... C-0032 ........ 28
RELAY A324-DM .......................................... C-0034-00 ..... 29
WBMC SELECTOR ........................................ APB0648 ...... 30
SPEED FLOW CONTROL VALVES .......................................... 31
HANDPUMP ............................................. A-0181 ........ 32
HANDPUMP SAFETY VALVE ................................ APB0815 ...... 33
FILTER. . . . ............................................. A-0182 ........ 34
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SECTION I LINEAR GAS / HYDRAULIC GATE VALVE OPERATOR
DESCRIPTION DWG.NO PAGE
XVIII VH LOCKING BLOCK ADJUSTMENT AND SERVICE ............................ 35
VH LOCKING BLOCK ...................................... APB0662 ...... 36
MECO REGULATOR...................................................... 37
END OF STROKE VENT VALVE DOWNWARD STROKE .......... C-0081 ........ 40
END OF STROKE VENT VALVE UPWARD STROKE ............. C-0083 ........ 41
LIMIT SWITCH: HONEYWELL.............................................. 42
FIELD SERVICE REQUEST AND CHECKLIST .................. I-0100 ......... 43
XIV NOTES ............................................................. 45
SECTION II SPECIFICS FOR PARTICULAR UNIT
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I SAFETY WARNINGS
1. OPERATING INSTRUCTIONS (Page 6)
This equipment exhausts gas as part of its operating cycle. Wear hand, ear, and eye
protection, and keep sparking devices and open flames away.
2. INSTALLATION (Page 7)
For final assembly over stem to valve, lifting lugs are to be used in combination with a two
leg sling with on shortening hook to lift the operator only.
3. INSTALLATION (Page 7)
Excess operator travel can cause damage to end of stroke (trigger) valve if over-travel
occurs and the trigger interferes with the component. The operator’s mechanical end stops
are preset at the factory for 90b travel.
4. START-UP CHECKS (Page 12)
If the unit has a fail or ESD (Emergency Shut Down) position, the failsafe or ESD controls
may have to be temporarily disabled, bypassed or overridden by AUTO / MANUAL selector
to prevent inadvertent valve operation.
5. SCHEDULED MAINTENANCE AND TESTING (Page 13)
DE-PRESSURIZE operator before attempting to service power gas filter. Check tank fluid
level or manual operation of handpump.
6. END OF STROKE ADJUSTMENT INSTRUCTIONS (Page 16)
Changing operator travel can cause damage to end of stroke (trigger) valve if over travel
occurs and trigger strikes component.
7. LINEAR OPERATOR MAINTENANCE (Page 16)
Gas / Hydraulic tanks should be drained and flushed if fluid is contaminated with scale, rust,
particulates, water, foam, or etc. Flush only with hydraulic fluid. Refill with filtered fluid.
8. MECHANICAL STOP ADJUSTMENTS (Page 10)
The upper and lower operator positions must be adjusted to ensure correct operation.
Please refer to the applicable section for details and further information.
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II OPERATING INSTRUCTIONS
NOTE: Refer to schematic drawing and list of components.
Refer to "Operating Procedure" diagram which is located inside the control package
cover on the unit. (Also reproduced on page opposite)
NOTE: Operating procedures for equipment with automatic switching capability vary with
particular applications. Refer to "OWNER'S PROCEDURES" for operators with
automatic or remote switching devices.
NOTE: The four valves needed for local manual operation are located on a manifold plate
inside the control package compartment. The handpump is located below the control
package compartment.
A) WITH POWER GAS or auxiliary nitrogen bottle present, appropriate supply shutoff valves
open, and both handles of lower hydraulic switching valves in vertical position against stops:
To Close Line Valve: Press and hold handle on upper left gas switching relay. Release
after line valve is closed.
To Open Line Valve: Press and hold handle on upper right gas switching relay. Release
after line valve is open.
B) WITHOUT POWER GAS, and with supply shutoff valve closed:
To Close Line Valve: Rotate handle on lower left hydraulic switching valve clockwise
against stop. Operate handpump to close valve. Return valve
handle to vertical position against stop when line valve is closed.
To Open Line Valve: Rotate handle on lower right hydraulic switching valve counter
clockwise against stop. Operate handpump to open line valve.
Return valve handle to vertical position against stop when line valve
is open.
Placing hydraulic switching valve in mid position at the end of handpump operation will allow the
handpump plunger to be returned to lowest position. Return valve handle to vertical position.
C) TO DISARM OPERATOR: Shut off supply valve and press handle on either upper gas
switching relay halfway to vent power gas.
III INSTALLATION
A) FIELD MOUNTING
Refer to typical Gas / Hydraulic Parts List (Gate Valve Operators) on page 19.
CAUTION: Line pressure tends to push valve stem outwards and could open a closed
NOTE: Mounting hardware may be in a separate box on shipping pallet / crate or
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valve unexpectedly. Perform installation and service with valve open if
possible.
inside panel cover of unit.
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INSTALLATION continued . . .
CAUTION: The operator is typically shipped in the horizontal position with the tops of the
Gas / Hydraulic tanks and tubing plugged or capped.
Mounting arrangements vary with particular valve, but are constructed as simply as possible.
In general:
1. Remove any existing gearing from valve after it is in desired position.
2. Position operator with handpump.
3. Install jam nut and or stop nut on valve stem, if applicable.
4. Connect operator to valve stem.
5. Bolt operator to valve.
6. Set operator end stops so operator and not valve stops the travel. Refer to Section III
Mechanical Stop Adjustments on page 10.
NOTE: Prior to handpumping the unit, reconnect the tubing at the top of the
Gas / Hydraulic tanks.
B) CONNECTIONS
1. User should provide a shutoff valve on supply and size supply lines to ensure draw
down when operating valve does not interfere unduly with any pressure sensing
devices. Supply lines should be located on top of the pipeline or header to avoid water
contamination of hydraulic fluid.
2. In the case of a volume tank with inlet check valve, user should install a relief valve on
tank to protect system against supply over pressure or thermal expansion.
3. Electrical connections to junction box are as per schematic and customer's electrical
drawing.
4. Conduit connection to limit or pressure switch, if field installed, to comply with all local
regulations (seal within 18 inches for explosion proof).
5. Leak tests should be performed upon initial application of low pressure of 100 psi.
CAUTION: Ensure the tubing located at the top of the Gas / Hydraulic tanks is
reconnected prior to any operation.
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IV MECHANICAL STOP ADJUSTMENTS
NOTE: Operator is shipped with upper and lower stops set for published valve stroke.
A) Stop adjustment with valve stem in (up) extended position.
1. Position operator so that it is 10 handpump strokes from the fully retracted position
(usual shipping position).
2. Measure the amount of allowable valve stem engagement in stem nut of connector.
Measure and mark this engagement on the valve stem.
3. Thread stem nut section of connector on to valve stem, while handpumping the operator
downward, until allowable engagement is reached.
4. Handpump operator for upwards travel until it becomes solid.
5. Check connector / stem nut swivel for looseness. If operator is against its’ mechanical
stop and not pulling the gate against the bonnet, the stem nut section of connector
should rotate on the valve stem a few degrees back and forth easily.
6. If not, continue to back off; thread off stem nut from the valve stem, while handpumping
the operator upward, until the actuator is solid against its’ stop and the stem nut section
of swivel has some looseness. Refer to step 5 above.
NOTE: Check valve stem engagement in the stem nut to ensure that it is adequate.
B) Operators with mechanical end cap stop design.
1. Should the operator reach its mechanical stop and the necessary stem nut looseness
cannot be achieved while handpumping, then the mechanical stop on the end cap of the
operator will have to be adjusted outward to allow for further operator travel in the
upward direction.
2. If the upward operator position is obtained, while handpumping, before the operator
stops on its’ mechanical stop, then the mechanical stop on the end cap of the operator
will have to be adjusted inward to limit operator travel.
C) Operators with connector stop design.
1. The connector is designed to stop against the cylinder plate to limit operator up stroke.
a) Loosen the connector setscrew and thread the connector up / down on the drive
rod as required, to obtain the required upper operator position and the necessary
stem nut looseness..
b) If necessary, loosen the stem nut setscrews and thread the stem nut up / down to
adjust the operator / gate valve lower position at down stroke limit.
c) Re-tighten setscrews.
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V PRESTART-UP CHECKS
A) OPERATOR
1. Verify unit has been mounted on valve properly. Gear flange mounting bolts, stem nut,
set screw(s) installed and secured.
NOTE: Mounting hardware may be in a separate box on shipping pallet / crate or
inside panel of cover of unit.
2. Inspect unit for damaged tubing during shipping or installation.
3. Valve position confirms with indicated position.
4. All switching valves in normal operating position as per DIAGRAM / INSTRUCTIONS.
5. If removed, cover bolts, limit switch / end of stroke mounting bolts have been replaced
and secured.
6. Limit switch / end of stroke valve TRIGGER(S), if removed for valve installation, have
been replaced and are properly set. SEE APPLICABLE SECTION IN SERVICE
MANUAL FOR INSTRUCTIONS.
B) CONNECTIONS
1. Pneumatic / hydraulic components connected as per SCHEMATIC enclosed or in
service manual supplied.
2. Power gas / signal gas connected in identified ports.
3. Electrical connections in junction box terminals are secure.
4. Wiring as per enclosed diagram or service manual supplied.
5. LIMIT SWITCH . . . remove cover . . .
a) Ensure wiring will not become tangled or hooked by cams during rotation.
NOTE: 'ZSO_' actuated at fully open position.
'ZSC_' actuated at fully closed position.
LOWEST 'ZS__' IN STACK IS ZSOA; the one next to operator.
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VI START-UP CHECKS
NOTE: If unit has a fail or ESD position, the ESD side of the controls may have to be
disenabled, enabled or overridden by AUTO / MANUAL selector.
To check operation in AUTO or MANUAL mode; temporarily remove the ESD COMPONENT
(pilot, solenoid, switching relay) signal line, plug / cap it so it does not bleed the system
during check out procedures.
A) If possible, manually operate unit to full open and close positions by:
a) handpump on unit
b) low pressure (100 psi) power gas applied to supply port.
When each position has been reached, CHECK:
1. Operator stop settings, if adjustment is required SEE APPLICABLE SECTION IN
SERVICE MANUAL.
2. Oil levels in tanks. SEE SERVICE MANUAL FOR CORRECT LEVEL FOR EACH
POSITION.
3. Limit switch / end of stroke actuated at correct locations.
B) Power gas supply, CONFIRM power gas supply PRESSURE.
1. Gas / Hydraulic rotary or linear - maximum operating pressure as per tank and operator
NAME PLATES or as specified by user.
C) Leak test by applying power gas supply and at end of stroke manually maintained power gas
on system for TWO MINUTES.
CHECK:
1. For leaks at supply points / fittings in supply line.
2. For hydraulic / air leaks at fittings while operator is operating.
D) To check manual and automatic operation
1. If unit has auto / manual selector place selector in "manual"
2. Open power gas supply valve or apply power gas to unit
3. Manually operate upper relays as per instructions to stroke unit to "open and close"
positions. Check to ensure there are no leaks at connections and no exhaust gas /
blowby after stroke is completed. During stroking, gas is exhausted but stops when the
operator reaches end of stroke.
4. Put selector in "AUTO” position.
a) Simulate automatic operation by energizing or de-energizing solenoid(s), and / or
switching relays.
b) Check for leaks/blowby at exhaust ports of component during operation. Limit
switch actuation and end of stroke venting.
c) Put operator in normal operating position for ESD / Fail operation check out which
follows below.
E) SHUT OFF POWER GAS SUPPLY, DISARM OPERATOR AS PER INSTRUCTIONS.
1. Replace and disconnect any tubing that was removed or connected to ESD
COMPONENT for above test.
2. Remove electrical jumper(s) installed to simulate "AUTO" operation unless required to
operate ESD device.
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START-UP CHECKS continued . . .
F) EMERGENCY SHUTDOWN / FAIL POSITION OPERATION CHECK OUT
1. Ensure operator is in normal operating position.
2. Apply / remove the required ESD signal to operate the unit.
3. Apply power gas supply to the unit, it should operate to ESD / Fail position.
NOTE: If unit has power gas storage bottle on it, you may want to install a gauge in gauge
port of regulator and check the consumption and number of strokes available.
G) RESTORE ALL TUBING AND WIRING AS PER FACTORY SHIPPED OR NORMAL
OPERATING CONDITIONS.
VII SCHEDULED MAINTENANCE AND TESTING
A program of scheduled maintenance and operational testing of the operator is recommended.
The following test and maintenance procedure should be performed at least once per year.
1. Drain accumulated moisture and contaminants from gas filter.
Refer to GENERAL SERVICE NOTES.
2. If step (1) indicates heavy accumulations, drain contaminants from GAS / HYDRAULIC
TANKS(S) and check tank levels. Refer to GENERAL SERVICE NOTES regarding TANK
LEVELS.
Consider replacing filter element(s) as it may be clogged with contaminants.
3. If line valve position must not be changed, if necessary remove valve stem key to disconnect
operator from valve before proceeding.
NOTE: With gate valve operator, decoupling is not recommended.
4. See "OPERATING INSTRUCTIONS" to ensure proper method of operation is followed.
5. Check manual operation with handpump. (if applicable)
a) There should be noticeable suction on the suction stroke, decreasing as the pump
cylinder fills, indicating suction lines are open and full of fluid.
b) Handle effort on the pressure stroke will depend on line pressure and line valve
position.
c) Pressure stroke should be smooth and feel solid, not spongy, indicating pressure lines
are open and full of fluid.
d) At the end of operator stroke (line valve open or closed) the handle should stop solid on
e) Test by applying 150 lb force for two minutes to the pump handle provided with the unit.
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the pressure stroke, indicating no bypass flow in operator or hydraulic components.
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SCHEDULED MAINTENANCE AND OPERATIONAL TESTING continued . . .
6. Check manual operation with power gas (if applicable)
a) Depress appropriate relay handle. There should be a momentary flow of gas from
exhaust port in intermediate position.
NOTE: Some effort (up to 50 lbs) should be required to fully depress handle,
indicating adequate supply pressure.
b) The operator should stroke smoothly, indicating GAS / HYDRAULIC tank levels are
okay and operator mechanicals are okay.
c) Fluid returning to the opposite tank during stroking will cause a continuous slight
exhaust gas flow from exhaust port, but which stops when the operator reaches end of
stroke. This indicates proper relay function and no bypass flow in operator or gas or
hydraulic components.
d) There should be no leaks of gas or hydraulic fluid.
e) Upon releasing relay handle, there should be a momentary rush of gas from exhaust
port as gas / hydraulic tank is vented.
7. Operating with power gas, check remote / automatic operation (if applicable).
NOTE: Ensure that adequate pressure and flow of gas, and correct hydraulic fluid levels
are present.
a) Shutoff valve should be open.
b) There should be no gas leaks.
c) Hydraulic speed control valves should be partially open.
d) With appropriate metre or gauge, check for correct signal condition.
e) Simulate remote or automatic switching.
f) During stroking of the operator, there should be no signal gas leakage indicating that
the signal section of the switching relay is okay.
g) Test the handpump safety feature. With the handpump handle in place and the
handpump in manual mode, while standing well clear
, apply power gas manually in the
same direction (open / close) as handpump selected and observe for any handpump
handle movement.
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