Emerson G4004.0, G01001.5, G4003.0, G5004.0, G7008.0 Installation And Operation Manual
...
Installation and Operation Manual
Dimension
Double-Acting Actuator
Product Data Sheet EHO
March 2015
EHO.01.05.EN, Page 2 of 2, Rev. 0
Part Number: VA001-507-32, Rev. 1
Release: August 2016
Bettis™ EHO (Electro-Hydraulic Operated)
Double-Acting Actuator
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Table of Contents
Section 1: Introduction
1.1 Scope .......................................................................................................... 1
1.2 General Information ................................................................................... 1
1.3 Safety Information ...................................................................................... 2
1.4 Abbreviation Definitions ............................................................................. 2
Section 2: Installation
2.1 Preparation ................................................................................................. 4
2.2 Valve Preparation ........................................................................................5
2.3 Actuator Preparation .................................................................................. 5
2.4 Lifting the EHO Actuator ............................................................................. 6
2.5 Installing the EHO Actuator on the Valve ...................................................11
2.6 Setting the Stroke Limit Stops ....................................................................11
2.7 Hydraulic Fluid .......................................................................................... 12
2.8 Accumulator (Optional) ............................................................................ 12
Table of Contents
August 2016
Section 3: Electrical Connections
3.1 Remove Separate Terminal Chamber (STC) Cover ..................................... 17
3.2 Sealing Cable/Conduit Entries ................................................................... 18
3.3 Recommended Terminal Connections ...................................................... 18
3.4 Separate Terminal Chamber (STC) Connections ........................................ 19
3.5 Replace Terminal Chamber Cover ............................................................. 19
3.6 External Earth/Ground Connections .......................................................... 19
3.7 Discrete Controlled Inputs Connection ..................................................... 20
Section 4: Set-up/Start-up Procedure
4.1 Preparation ............................................................................................... 21
4.2 Initial Check of the Unit ............................................................................ 22
4.3 Initial Connections .................................................................................... 22
4.4 Hand Pump ............................................................................................... 22
4.5 Hydraulic Test ........................................................................................... 25
4.6 Check Rotation ......................................................................................... 26
4.7 Limit Switch Adjustment ........................................................................... 27
4.8 Function Test ............................................................................................ 30
4.9 Other Options ........................................................................................... 32
Section 5: Operation
5.1 Hydraulic Power System ........................................................................... 33
5.2 Reservoir ................................................................................................... 33
5.3 Main Components .................................................................................... 33
5.4 Functional Description .............................................................................. 37
Table of Contents
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Table of Contents
August 2016
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Section 6: Pushbutton Module (PBM)
6.1 Selector Knob and Control Pushbuttons ...................................................40
Section 7: Troubleshooting
Section 8: Hazardous Area Classification and SIL Certification
Section 9: Weights and Dimensions
9.1 EHO Standard Double Acting .................................................................... 43
Section 10: Sample Wiring Diagram
10.1 2-Way Electric Powered By an Electro-Hydraulic Power Unit ..................... 44
10.2 2-Way Electric With Emergency Shutdown Feature Powered By an Electro-
Hydraulic Power Unit ................................................................................ 45
II
Table of Contents
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Section 1: Introduction
1.1 Scope
This manual is offered as a guide to be used along with locally approved and safe
practices to install, operate, service and maintain the Bettis EHO Actuator. Carefully
follow the instructions in this manual and make sure you install the actuator correctly
and according to your requirements.
1.2 General Information
1.2.1 Overview
The Bettis EHO is a self-contained, quarter-turn, valve actuator that combines proven
technologies from Emerson’s Actuation Technologies. The actuator has been designed
for
critical shutdown applications where reliability is crucial. The EHO utilizes a dependable
spring-return actuator for the Fail-safe stroke combined with an integral hydraulic power
pack and electronic control module.
Section 1: Introduction
August 2016
The EHO accepts a wide range of single-phase, three-phase or DC power sources, also
solar panels are available for areas without electrical power. A hydraulic hand pump can
be used to stroke the actuator during commissioning or in the event of an emergency
power loss.
Electronic modules are contained within an explosion proof, IP68 enclosure and all
electronic components are isolated from the customer connection terminals.
The EHO provides a compact design with actuator and control components that have
been field proven for decades in critical service applications.
1.2.2 Product Attribute
• Easy installation – Bettis™ EHO actuator is a totally self-contained system and
designed for compactness and adaptable to new or existing valves.
• Bettis™ G-Series hydraulic double-acting or spring-return fail-safe actuator
• Shafer™ hydraulic control technology
• EIM™ electronics and communication technology
• Multiple input power options with either AC or DC
• Local lockable Remote/Local/Offline switch
• Local open/close/stop switch
• Partial stroke test
• Fast speed of operation to Fail-safe position if required
• Emergency shutdown – independent safety circuits and solenoid valve
• Dual sealed Separate Terminal Chamber, allows installation wiring to be
performed or fuses to be replaced without exposing control components to
hostile environmental conditions.
Introduction
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Section 1: Introduction
August 2016
• Control enclosure is made of low-copper aluminum alloy, powder-coated, salt
resistant also rated for IP68 ingress protection.
• Hydraulic hand pump manual override
• Accumulators (optional)
• Solar power (optional)
• Operating pressures up to 3000 psi with standard components
• Easy control over actuator stroking speeds – The stroking speed is controlled
through adjustable hydraulic flow control valves. This enables field personnel to
easily adjust actuator stroking speed to comply with field requirements.
1.3 Safety Information
Safety notices in this manual detail precautions the user must take to reduce the risk of
personal injury and damage to the equipment. The user must read these instructions in
their entirety. Failure to observe these safety notices could result in serious bodily injury,
damage to the equipment, void of the warranty. Take special notice of all tags, warning
labels and instructions presented on the actuator. These may provide more specific and
significant information regarding the actuator than this general manual.
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
It is the responsibility of the user to ensure proper safety practices are utilized. Always
take necessary precautions and use proper protective equipment when dealing with
compressed gasses, compressed hydraulic fluid, pinch points and electricity.
Safety notices are presented in this manual in three forms (Warning, Caution and Note)
as follows:
WARNING:
Alerts user of potential danger; failure to follow the warning notice could result in
serious personal injury or death.
CAUTION:
Identifies precautions the user must take to avoid personal injury or equipment damage.
NOTE:
Highlights information critical to the user’s understanding of the Bettis EHO valve
actuator installation or operation.
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Introduction
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
1.4 Abbreviation Definitions
Abbreviations used in this manual and their definitions are listed in the table below:
Table 1. Abbreviation Definitions
Abbreviation Definition
IOM Installation Operation Manual
SCH Self-Contained Hydraulic
ESD Emergency Shutdown
FS Fail-safe
SR Spring-Return
DA Double-Acting
MAWP Maximum Allowable Working Pressure
MOP Maximum Operating Pressure
STC Separate Terminal Chamber
PBM Pushbutton Module
LDM Local Display Module
RDM Remote Display Module
CBM Circuit Breaker Module
PCB Printed Circuit Board
LS Limit Switch
PS Pressure Switch
NC Normally Closed
NO Normally Open
CCW Counterclockwise
CW Clockwise
OL Overload
PPE Personal Protective Equipment
GA General Arrangement Drawing
Section 1: Introduction
August 2016
Introduction
3
Section 2: Installation
August 2016
Section 2: Installation
2.1 Preparation
2.1.1 Delayed Usage
If for any reason the actuator is not to be installed immediately, Bettis recommends the
following procedures. Failure to comply, with recommended procedures, could lead to
actuator malfunction and possibly void the warranty. For storage procedures exceeding
one year, consult Bettis for further recommendations.
As shipped from the factory, the Bettis EHO actuator is an inherently weatherproof unit,
providing that all compartment covers and cable entry plugs remain intact. The actuator
should be immediately stored in a clean, dry warehouse, free from vibration and rapid
temperature changes, until it can be installed and energized.
If the actuator must be stored outside, store it off of the ground at an elevation
sufficient to prevent it from being immersed in water or buried in snow. Check for any
unpainted or exposed metal surfaces and make sure they are protected with a coating
of grease to prevent any corrosion. Cover the actuator to prevent damage from site
debris.
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
2.1.2 Tools and Materials Required
To complete these procedures, you will need the following documentation for the
Bettis EHO Actuator and items indicated in the table below:
• General Arrangement Drawing
• Bill of Material
• Hydraulic System Schematic
• System Wiring Diagram
Table 2. Tools and Material Requirements
Tools and Material Requirements
Primary Power Source for the EHO
(check the EHO System Electrical Diagram for requirements)
Supplemental quantity of hydraulic fluid, if needed
(See 2.7, Hydraulic Fluid and EHO specification, for required fluid type)
Nitrogen Source (if an Accumulator is supplied with the EHO)
Hand Tools: complete complement of open end (SAE and metric) wrenches, screw driv-
ers Philips and flat blade and a set of hex wrenches
Chains and lifting straps that are inspected and certified for the weight of the EHO
Actuator (check shipping weights)
Sealant for all cable and conduit entries (approvable by the National Electric Code or
your country standard and applicable local codes)
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Installation
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
2.2 Valve Preparation
2.2.1 Remove Valve Gearing if so equipped.
2.2.2 If valve is equipped with stops, remove valve stem extension housing. Examine
the valve stops to ensure no foreign material is present that would restrict
normal travel of the valve. Some valves are equipped with inspection ports in
the valve housing for ease in examining the stops.
2.2.3 Check alignment of stem key slot to the position of the valve. Normally
with the valve in the open position, the key slot is in line with the run of the
pipeline.
With the valve in the closed position, the key slot should be 90° to the run of
the valve.
2.2.4 The EHO Actuator may be mounted to the valve at any time regardless of
whether or not the valve is under pressure.
2.3 Actuator Preparation
Section 2: Installation
August 2016
2.3.1 Once the EHO Actuator is uncrated and cleaned for installation, check to ensure
there will be no interference with piping or other structure when the actuator is
properly mounted to the valve.
NOTE:
At this point, check to see that when the actuator is mounted to the valve and in its final
orientation, the outboard end of the power cylinder positioned below the Hydraulic
Reservoir Breather. If this is not possible, contact Bettis for further instructions on piping
to elevate the breather. See Vertical Mounted Actuator 2.4.4.
2.3.2 Check that all mounting materials such as fasteners, adapters, brackets etc. are
on hand and ready for use.
2.3.3 Check the actuator and valve to see that they are in the same relative position,
that is either open or closed. If the actuator has to be moved, use the hand
pump provided. For hand pump operation, remove the plug in the reservoir and
install the breather (refer to 4.4 Hand Pump Operation).
2.3.4 All spring-return EHO Actuators are supplied with a small accumulator for
protection from thermal-expansion of the hydraulic fluid. This accumulator is
pre charged at the factory and will not need service during installation or startup of the actuator.
CAUTION:
Be aware, while preparing to and lifting the actuator, the Thermal Compensating
Accumulator contains high-pressure nitrogen. Use care not to damage the accumulator
or its attachments.
Installation
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Section 2: Installation
August 2016
2.4 Lifting the EHO Actuator
NOTE:
All Bettis EHO G-Series Considerations
When handling any EHO G-Series, be aware of tubing, accessories, hand pump,
accumulators, Pushbutton module and control enclosures. Straps and chains can become
entangled and cause damage to these components. Never use chains on the spring
cartridge as it may warp and cause the actuator not to function correctly or may cause
personal injury.
NOTE:
Do not use hydraulic tubing and electrical cable for lifting.
CAUTION:
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Be sure to use appropriately rated crane/hoist and straps/chains to raise and lower
the actuator.
2.4.1 G01X – G2 and All E-Series Actuators
2.4.1.1
Figure 1 G01 – G2 and all E-Series Actuators with Horizontal Pipeline
and Vertical Stem
Horizontal Pipeline Vertical Stem
The small G-Series and all E-Series actuators mounting on a horizontal
pipeline with a vertical valve stem should be supported under the
“C” bracket and a two-point attachment for balance. A strap may be
attached to the stabilization tab on the spring module to balance the
unit while lifting. The weight of the actuator must be supported at the
“C” bracket, not the stabilization tab. See Figure 1.
CAUTION:
Never lift the actuator with a valve attached. Always handle actuator/valve assemblies
by attaching lifting equipment to the valve only.
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Installation
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Section 2: Installation
August 2016
2.4.1.2
Horizontal Pipeline Horizontal Stem
The small G-Series and all E-Series actuators mounting on a horizontal
pipeline with a horizontal valve stem should be supported on
the ends of the drive module. A strap may be attached to the
stabilization tab on the spring module to balance the unit while
lifting. The weight of the actuator must be supported at the drive
module, not the stabilization tab. See Figure 2.
Figure 2 G01 – G3 and all E-Series Actuators with Horizontal
Pipeline and Horizontal Stem
2.4.2 G3-Series Actuators
2.4.2.1
Horizontal Pipeline Vertical Stem
The G3-Series actuator mounting on a horizontal pipeline with a
vertical valve stem should be supported at the ends of the drive
module. A strap may be attached to the stabilization tab on the spring
module to balance the unit while lifting. The weight of the actuator
must be supported at the drive module, not the stabilization tab. See
Figure 3.
Installation
Figure 3 G3 with a Horizontal Pipeline and Vertical Stem
CAUTION:
Never lift the actuator with a valve attached. Always handle actuator/valve assemblies
by attaching lifting equipment to the valve only.
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Section 2: Installation
August 2016
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
2.4.2.2
Horizontal Pipeline Vertical Stem
The G3-Series actuator mounting on a horizontal pipeline with a
horizontal valve stem should be supported on the ends of the drive
module. A strap may be attached to the stabilization tab on the
spring module to balance the unit while lifting. The weight of the
actuator must be supported at the drive module, not the stabilization
tab. Be sure to use appropriately rated crane/hoist and straps/chains
to raise and lower the actuator. See Figure 2 above.
2.4.3 G4 – G7 Series Actuators
2.4.3.1
Horizontal Pipeline Vertical Stem
The G4 – G7 Series actuators mounting on a horizontal pipeline with
a vertical valve stem should be supported using the lift lugs attached
to the drive module. A strap may be attached to the stabilization
tab on spring module to balance the unit while lifting. The weight of
the actuator must be supported by the lugs at drive module, not the
stabilization tab.
See Figure 4.
Figure 4 G4 – G7 with a Horizontal Pipeline and Vertical Stem
CAUTION:
Never lift the actuator with a valve attached. Always handle actuator/valve assemblies
by attaching lifting equipment to the valve only.
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Installation
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Section 2: Installation
August 2016
2.4.3.2
Horizontal Pipeline Horizontal Stem
The G4 – G7 Series actuators mounting on a horizontal pipeline with
a vertical valve stem should be supported using the lift lugs attached
to the drive module. A strap may be attached to the stabilization
tab on spring module to balance the unit while lifting. The weight of
the actuator must be supported by the lugs at drive module, not the
stabilization tab.
See Figure 5.
Figure 5 G4 – G7 with a Horizontal Pipeline and Horizontal Stem
CAUTION:
Never lift the actuator with a valve attached. Always handle actuator/valve assemblies
by attaching lifting equipment to the valve only.
Installation
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Section 2: Installation
August 2016
2.4.4 Mounting the Actuator in a Vertical Orientation on a Horizontal Stem
When mounting an Bettis EHO Actuator in a vertical orientation, the Spring Module
must be positioned up. The actuator may be supported by using two straps in the
configuration shown in Figure 6. A third strap or small chain may be attached to the
stabilization tab on spring module to balance the unit while lifting. The weight of the
actuator must be supported by the straps running over the spring module and under the
drive module flange.
Figure 6 Vertical Actuator Lift
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
CAUTION:
Never lift the actuator with a valve attached. Always handle actuator/valve assemblies
by attaching lifting equipment to the valve only.
NOTE:
When a vertical EHO Actuator is mounted to the valve, and in its final orientation, the
spring module must be up and outboard end of the power cylinder positioned below
the Hydraulic Reservoir Breather. If not possible, contact Bettis for further instructions
on piping to elevate the breather.
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Installation
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
Section 2: Installation
2.5 Installing the EHO Actuator on the Valve
The actuator will be bolt-mounted directly to a bracket or adaptor that will be bolted
securely to the mounting flange top works of the valve.
2.5.1 Check to see that the dimensions of the bracket or adaptor are suitable for use
with the valve mounting flange and stem.
2.5.2 Check valve direction of rotation and the actuator direction of rotation to see
they match (for example: CW = close, CCW = open).
2.5.3 Check to see the actuator and valve are in the same relative position (see 2.3.3).
2.5.4 Check all mounting surfaces, they must be clean and free of debris to permit
proper fit up.
2.5.5 Prior to mounting, grease the coupling bore and the bore of the actuator.
NOTE:
Do not apply grease to the mounting flange surfaces on the valve or the adaptor.
August 2016
2.5.6 Install the stem key and grease it (keys may be held in place with tape).
2.5.7 Install the coupling onto the stem and stem key.
2.5.8 Install the coupling key and grease it.
2.5.9 Carefully align the coupling and key to the bore and keyway in the actuator
and slide the actuator onto the coupling until the adapter (bracket) bottoms
out on the valve bonnet.
NOTE:
Ensure the adapter seats out on the valve bonnet, without interference, before
installing fasteners.
2.5.10 Use the required fasteners to firmly attach the adapter to the valve bonnet.
Tighten the fasteners to their manufacturer’s recommended maximum torque
(dry or lubricated).
2.6 Setting the Stroke Limit Stops
2.6.1 The Bettis G-Series is provided with bi-directional travel stops allowing 80° to
100° total travel (+/- 5° adjustment at each end of the 90° stroke).
2.6.2 Actuators are shipped from the factory with the travel stops adjusted for
approximately 90° rotation. Generally, it is necessary to make slight travel
stop adjustments once the actuator is installed on the valve. Refer to the valve
manufacturer's recommendations for specific requirements.
2.6.3 When the valve has internal stops, the actuator stops must be set so that the
load is applied to them, not the valve stops.
2.6.4 If adjustment is required, use the hand pump to move the actuator off the stop
at the closed position before attempting to turn the adjusting screw (refer to
4.4, Hand Pump Operation).
Installation
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Section 2: Installation
August 2016
CAUTION:
Always use the hand pump to move the actuator off the stop before attempting to turn
the adjusting screw.
2.6.5 With the closed position stop set, use the hand pump to move the actuator
to the other end of the stroke and check the stop position. If adjustment is
required, slowly open Manual Bypass Valve (Lockable) (19) just enough to allow
the actuator to spring-return off the stop before adjusting.
2.7 Hydraulic Fluid
Bettis Electro-Hydraulic Operated actuators are shipped with the reservoir filled to
operation level. Before commissioning and periodically afterwards, check to see the
fluid level is correct. The oil fill cap is provided with a dipstick marked with a green and a
red mark. When the optional accumulator is drained of fluid and the actuator is at Failsafe Position, the oil should be at the green mark. The reservoir also has a sight gauge
for the purpose of seeing fluid is present. Should fluid need to be added or replaced, use
only factory approved hydraulic fluid.
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
This specification covers hydraulic fluids which are approved by engineering for use in
Bettis Electro-Hydraulic Operated actuator in a temperature range from -40°F to 140°F
(-40°C to 60°C).
2.7.1 Approved Fluids
•
•
Although other brands of fluid matching the same specifications may be used, to
maintain the warranty and ensure trouble free operation, always check with the factory
before substituting any other fluid.
Standard Fluid [use with -20°F to 140°F (-29°C to 60°C) applications]
— ConocoPhillips Megaflow™ AW HVI Hydraulic Oil 22
— Shell Tellus S2 V 22
— Mobil DTE 10 Excel™ 22
Low Temperature Fluid [use with -40°F to 140°F (-40°C to 60°C) applications
— Mobil Univis™ HVI 13
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Installation
Installation and Operation Manual
Part Number: VA001-507-32, Rev. 1
2.8 Accumulator (Optional)
2.8.1 Introduction
The Bettis EHO Actuator may be equipped with an accumulator to enable manual
operation of the actuator if there is a loss of electrical power. Accumulators always
have the nitrogen pressure drained for shipping (except for Thermal Compensating
Accumulator see 2.3.4).
NOTE:
When using this procedure, refer to the Bettis EHO Actuator General Arrangement
drawing and Hydraulic Schematic for the unit being worked on. (Schematic below is for
illustration only.)
WARNING:
Section 2: Installation
August 2016
This unit contains high-pressure hydraulic fluid and nitrogen gas. Exercise caution when
performing any type of maintenance. Wear proper safety attire and required personal
protective equipment, including safety glasses.
2.8.2 Accumulator Pre-charge
a. Locate Isolation Valve (F) (Nitrogen Blow Down and Fill) for the
Customer Nitrogen Fill Connection, called out on the General
Arrangement Drawing and Hydraulic Schematic (see illustration below).
b. Close the Isolation Valve (F) and remove the pipe plug from the adaptor.
NOTE:
The Adaptor is tapped with a 1/4-NPTF thread.
c. Ensure 3-way Isolation Valve (D) is turned fully counterclockwise.
d. Slowly open Isolation Valve (Accumulator drain) (E) and drain all the
fluid back to the reservoir.
e. Connect a nitrogen supply to the Customer Nitrogen Fill Connection at
Isolation Valve (F).
f. Open the Isolation Valve (F) (Nitrogen Blow Down and Fill) and
charge the Accumulator, to the pre-charge pressure as specified by
the Pressure versus Temperature Graph on the General Arrangement
Drawing.
NOTE:
For temperatures, which do not appear on the graph, the formula to calculate the
pre-charge pressure shown on the General Arrangement Picture Assembly should be
used.
Installation
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