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FlowAct 503
User Instructions
76 pgs7.44 Mb0

Flowserve FlowAct Series, FlowAct 1502, FlowAct 253, FlowAct 503, FlowAct 3002 User Instructions

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USER INSTRUCTIONS
FlowAct
Diaphragm Linear Actuator
FCD VLENIMFACTA4 10/16
Installation
Operation
Maintenance
Experience in Motion
Diaphragm Linear Actuator - FlowAct
Diaphragm actuators take the form of a flexible diaphragm, placed between two casings. The upper section of the two chambers is designed pressure tight, the lower chamber holds a spring opposing the force generated within the pressure chamber of the actuator. The controlled air supply is connected to the pressure tight chamber, and an increase or decrease of the air pressure results in a positioning force of the stem. This kind of actuator is called single acting with spring return positioning force for linear motion. The linear motion / stroke is limited by a stroke range from 10 - 100 mm and a positioning force range from 500 - 60.000 N dependent on the actuator size. The actuator parts are designed so that the actuator can be assembled in two fail safe positions, close or open. Simplicity of design reduces maintenance and parts inventory costs. It is ideally suited for flow and pressure control of liquid and gas media in oil and gas, power, chemical and petrochemical processing and related industries. The FlowAct is manufactured to ISO 9001 standards.
The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Flowserve FlowAct diaphragm linear actuators. This instruction manual does not include specific product design data. Such data can be found on the actuator’s serial plate or specification documents; additionally, dimensional information can be found in the FlowAct technical bulletin. Procure needed documents as necessary before you begin any work on the valve.
Figure 1: FlowAct - Actuator, Spring close
User Instructions cannot deal with all possible situations and installation options. It is required that only trained and qualified technicians are authorized to adjust, repair or work on diaphragm linear actuators, positioners and other accessories. Review this bulletin prior to installing, operating or performing any maintenance on the actuator. Additional Installation, Operation, and Maintenance Instructions (IOMs) cover other features (such as positioners and other accessories).
To avoid possible injury to personnel or damage to actuator parts, WARNING and NOTICE indicators must be strictly followed. Modifying this product, substituting non-factory parts or using maintenance procedures other than outlined could drastically affect performance and be hazardous to personnel and equipment and may void existing warranties. This manual should be used in conjunction with applicable local and national laws. Failure to comply with User Instructions will render the manufacturer’s guarantee and liability null and void. Unless otherwise agreed, the manufacturer’s general terms and conditions of sale shall apply.
Read the user instructions carefully before use.
Keep for future reference.
Figure 2: FlowAct - Actuator, Spring opens
Contents
1 Scope of Manual 3 7 Storage 4 13 Troubleshooting 12 - 13
2 Intended Use 3 8 Unpacking 4 - 5 14 Operating the Handwheel 13
3 Product Identification 3 9 Installation 5 - 8 15 Disassembly and Reassembly 13 - 73
4 Modification 3 - 4 10 Assembly on valve 8 - 10 16 Torque Requirements 74
5 Safety 4 11 Actuator Quick-Check 10 - 11 17 Lubricants 74
6 Packaging and Transport 4 12 Actuator Maintenance 11 - 12 18 Disposal 75
2
1 Scope of Manual
The following user information covers the FlowAct diaphragm linear actuator:
• Preferable for Flowserve - Villach valve product lines
• For the product range of
Type Positioning Force (N) Stroke (mm) 253 500 - 12 500 10 - 20 503 1 000 - 25 000 20 - 40 701 1 400 - 35 000 20 - 60 1502 3 000 - 60 000 20 - 100 3002 6 000 - 60 000 40 - 100
• Air supply max. 6 bar or as indicated on the type plate
• Protection class IP 54, with air purging IP 64
• Without or with attachments like:
- top mounted handwheel
- top mounted adjustable stroke limitation - max. 39 kN
- side-mounted handwheel - max. 39 kN
- central-mounted handwheel
components to match each application. There are two fail safe positions, close or open without or with attachments.
The FlowAct is designed in compliance with EN 1349:2009
- Industrial Process Control Valves (DIN EN 1349 and VDE 0409-1349).
The FlowAct actuator is designed for use in MODERATE and WORLDWIDE environmental conditions, standard ambient tem­perature range -40°C to +80°C (-40°F to 176°F). A special ver­sion is available with conditions up toup to -60°C, air humidity up to 93% non-condensing, air pollution up to 300 µg/m3, (un­less restricted by the accessories).
The product offering may include optional ancillary equipment, such as positioners, air-filter regulators, solenoid valves, limit switches or boosters. Digital, I/P, or pneumatic positioners can be mounted direct or with a mounting bracket. Refer to the relevant manufacturer‘s user instructions for information regarding other ancillary equipment.
3 Product Identification
• Comes with or without ancillary equipment
2 Intended Use
WARNING
rated for specific application conditions. Before installa­tion, check the serial number and / or the tag number to en­sure that the valve and actuator being installed are correct for the intended application. Do not use the valve assem­bly outside of its rated design limits. Exceeding the design limits may cause hazardous conditions including leakage of the process media or rupture of the pressure boundary resulting in possible process loss, equipment or environ­mental damage, or serious personal injury or death.
Specific product design data can be found on the actuators serial plate, data sheet and the calculation sheet (in acc. to the IEC 60534-7:2010).
The FlowAct handles a wide variety of general service ap­plications.
Diaphragm linear actuators are pressure vessels designed and
Each FlowAct diaphragm linear actuator comes with an at­tached serial plate which includes key information specifically for each actuator:
Figure 3: Serial Plate (Example)
The same serial number shown on the plate will appear on all FlowAct data sheets, dimensional drawings, bills of material, and spare parts lists. Other information located on the serial plate is self-explanatory for the FlowAct actuator.
You can download .pdf versions of the FlowAct documenta­tion including a sales brochure, technical bulletin and user instructions at www.flowserve.com. It is the user’s respon­sibility to keep this and related documentation on file and ac­cessible for the FlowAct product.
The FlowAct consists of the actuator, yoke and attachments and accessories. The actuator is designed with a high level of interchangeability allowing the user to assemble the great­est possible number of variations from a minimum number of
4 FlowAct Modification
FlowAct linear actuators are generally delivered as tested and assembled units.
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Unauthorized modification of the FlowAct dia­phragm linear actuator voids the product test certification and product warranties, could dras­tically affect product performance and could be hazardous to personnel and equipment.
NOTICE
in compliance with all test routines, guidelines and engi­neering standards.
Before FlowAct re-installation, all neces­sary tests must be repeated and recorded
5 Safety
Safety terms - WARNING and NOTICE - are used to highlight specific dangers and / or provide additional information that may not be readily apparent in the User Instructions. WARNING directions must be strictly followed.
follow HPE standards. (Nonreturnable packaging may contain up to 90% recyclable materials.)
7 Storage
Maximum storage time for diaphragm linear actuators is 2 years at 25 °C.
NOTICE
Upon arrival on site, store the FlowAct actuator on a solid base in a cool, dry closed room. Until its installation, the actuator must be protected from the weather, dirt and other potentially harmful influences.
Do not remove the protective covers from the air supply con­nection of the actuator or from the instrument and accesso­ries until the actuator is ready for installation at the site.
Rubber becomes brittle, lubricants become resinous, see also ISO 2230.
WARNING
death and substantial property damage can occur if proper precautions are not taken.
NOTICE indicates practices or provides
NOTICE
additional technical information.
or
WARNING indicates that severe personal injury,
Grey fields indicate safety-related informations.
6 Packaging and Transport
Pay close attention to shipping marks and transport pictograms.
Careful packing, loading and transport arrangements are re­quired to prevent products from being damaged during trans­port. Standard packaging includes a cardboard box, with or without a wooden pallet base as needed. Special packaging may include a wooden box. Packaging may use cardboard, plastic wrap, foam, or paper as packing material. Filling mate­rial may be a carton type or paper.
8 Unpacking
Hoisting and lifting are inherently dangerous activities and require safe rigging and proper training to mitigate hazards. Use standard in­dustry safety practices, personal protection, and warranted lifting devices.
WARNING
tuator. Do not allow the actuator assembly to rotate during removal. Do not stand under suspended loads. Failure to do so can cause serious personal injury and damage the actuator or nearby equipment.
NOTICE
low the sling to touch the stem, travel indicator or peripheral equipment. Observe the maximum permitted carrying capacity.
1. Check the packing list against materials received to ensure all components and accessories are present.
Be aware that the center of gravity may be above or beside the lifting point. Do not al-
Crushing hazard ! Arrange rig­ging to prevent tipping of the ac-
Shipping marks display product and package dimensions and weight (for further information request Packaging and Send­ing Instructions, Form L 002). Packing guidelines for export
4
2. Place and hook a double-leg sling (if necessary a triple­leg sling) into the lifting rings mounted on the actuator.
3. You can alternatively place a sling around the actuator case just above the yoke.
4. Upon removing the actuator from the packaging, we recommend that you:
• Promptly touch up any damage to the paint that of-
fers corrosion protection.
• Contact your shipper immediately to report any
damage.
• Call your Flowserve representative if you experience
any problems.
Do not remove the protective covers from the air supply connection of the actuator or from the instrument ports of the actuator and accessories until the actuator is ready for installation at the site.
Figure 4: Triple-Leg Sling (Example)
9 Installation
The actuator must be installed and commis­sioned by qualified staff - personnel who are fa­miliar with the installation, commissioning and operation of this product and possess the rele­vant qualifications in their field of activity.
Prior to installation of the actuator, we require, that you check the following conditions to reduce the risk of malfunction and safety related incidents.
No. Check Possible malfunction or safety related incident
1 Confirm that the nominal / operational data on the
serial plate matches the operational data of the facility.
An operational mismatch can cause considerable damage to the actuator or may lead to a failure at the facility.
Table 1: Basic safety massages for installing the actuator (continued on next page 6)
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No. Check Possible malfunction or safety related incident
2 Confirm that the ambient temperature is not elevated
permanent above 160 °F (70 °C)(unless restricted by the accessories).
3 Confirm that the air supply and instrument signal
lines are dry and clear of dirt and oil.
4 Confirm that the actuator and valve can be installed in
an upright position.
5 Confirm that the yoke and needed parts are available
for mounting on the valve.
6 Confirm that the valve stem and connecting parts
match.
7 Confirm the actuator has enough overhead clearance
to disassemble the valve from the pipeline.
A sustained exceeding of the permissible ambient temperature of 18 °F (10 °C) may halves the lifetime of non-metallic com­ponents, such as diaphragms, O-rings and scraper rings.
At a minimum, the instrument air must conform to ISA- 7.0.01­1996 (ISO 8573-1 Compressed Air - Class 2) requirement or those of the accessory manufacturer.
Non-upright positioning may result in premature wear.
Yoke - connection dimensions see page 7
Yoke - connection dimensions see page 7.
Minimum clearance zone see page 8
8 If there is an unused air connection ensure that it is
properly sealed (see page 7).
9 Confirm removal of all hazards and ensure appropriate
protective measures are in place.
10 Confirm the valve / actuator is grounded in order to
prevent an electrical discharge.
11 Throttling control valves are typically equipped with
a pneumatic actuator and valve positioner. Refer to the appropriate positioner manual for connections and maximum air supplies.
The venting chamber of the pneumatic actuator is always equipped with a venting plug. The pneumatic actuator types 253, 503 and 701 have two air connectors joining the pres­sure-tight actuator housing. One of this air connectors is used to control the actuator depending on the mounted accessories. The remaining connector on the actuator (S) or on the yoke (T) must be appropriately sealed. This feature is not applicable for type 1502 and 3002.
none
Noncompliance may result in electrical discharges.
The air supply must be limited to less than 87 psig (6 bar) per the actuator serial plate. An air filter regulator should be installed to ensure that the supply pressure to the pneumatic actuator does not exceed the air supply pressure indicated on the serial plate.
Table 1: Basic safety massages for installing the actuator
After these requirements are confirmed the actuator can be installed and connected to the valve.
6
62
~ M
Stroke
50
62
10
11
14
2 x M8
T Internal Air Supply
Yoke - connection dimensions (mm)
S
External Air Supply
VDI/VDE 3847
interface
45
T
G
Supply
HY
Ø B
Ø D
Additional interface for MULTI function yoke only Additional internal air supply for IAS and MULTI-yoke only
14
2 x M8
50
Air
Actuator Size
250 500 700 1500 3000
G 3/8 (Plug acc. to DIN 908 & O-ring 10x2 mm - if appl.)
T
G 1/4 (Plug acc. to DIN 906 - if applicable, G 1/2 - DVGW)
S
11
10
T Internal Air Supply
-
G 1/2
Yoke dimen­sions
Size Stroke Ø B ~ M G T Ø D H
250
500
700
1500 20
3000 40 82 140 M16 29 105 25 82 140 M20 29 105 25
10 - 65 110 M12 23 95 20 - -
20
20
40 82 140 M20 22 110 25 82 140 M16 25 115 25 82 140 M16 16 115
20
40 82 140 M20 22 110 25 82 140 M16 25 115 25 82 140 M16 16 115 25 82 140 M20 20 115 25
60 82 148 M20 34 110 25
40 82 140 M16 29 105 25 82 140 M20 29 105 25
60 82 150 M20 29 105 25 -
80 82 140 M20 29 105 25 82 140 M20 29 105 25
100 82 140 M20 29 105
60 82 150 M20 29 105 25 -
80 82 140 M20 29 105 25 82 140 M20 29 105 25
100 82 140 M20 29 105 25 -
1)
ATTENTION: FlowPro with Nominal Size DN 25 or 1”, Stroke 20 mm:
IAS-Yoke for MULTI-Yoke for NAMUR-Yoke for
Valtek GS FlowTop, Valtek CS FlowTop FlowPro
Y Ø B ~ M G T Ø D HY Ø B ~ M G T Ø D HY Ø B ~ M G T Ø D HY
49 106 M12 18 75 20
65 106 M16 18 90 20
49 144 M12 54 75 20
65 145 M16 59 90 20
49 144 M12 54 75 20
65 145 M16 59 90 20
-
65 105 M12 23 95 20 65 105 M12 12 95 20 82 150 M16 16 115 25
65 105 M12 23 115 20 65 105 M12 16 95 20 82 150 M16 16 115 25
25 82 140 M20 20 115 25
65 105 M12 23 115 20 65 105 M12 16 95 20 82 150 M16 16 115 25
82 150 M20 20 125 25 -
65 105 M12 29 110 20 82 150 M16 20 110 20
­25 -
Packing Design -> adjustable -> Ø B = 65 mm, M = 105 mm, G = M12, Ø D = 95 mm and HY = 20 mm only ! Packing Design -> spring loadet -> Ø B = 82 mm, M = 170 mm, G = M12 only !
Table 2: Basic safety massages for installing the actuator
1)
, VariCool
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Minimum Clearance Zone
~ 180 mm
for actuator
~ 7.1 inch
Removal space
~ H
valve
Height of
~ R
Face to face
Figure 5: Overhead clearance drawing
~ R ~ H
Actuator Size
250 mm 135 195 290 - 335 595
500 mm 180 195 330 - 460 870
700 mm 205 205 345 - 600 925
1500 mm 275 - 415 685 800 -
3000 mm 275 - 415 685 1140 -
without
accessories
Table 3: Overhead clearance dimensions / drawing
accessories
direct mounted
accessories
NAMUR -
mounted
dimensions
side mounted
hand wheel
with
without
hand wheel
10 Assembly on valve
structions using only original equipment manufacturer
The FlowAct diaphragm linear actuator is al­lowed to be assembled and reassembled only by qualified staff - personnel who are familiar with assembling, reassembling, installation and commissioning of this product, and possess the relevant qualifications in their field of activity.
8
When performing repairs, personnel are to follow these in-
(OEM) spare parts and recommended special tools to ensure the reliability of the FlowAct diaphragm linear actuator.
Only Flowserve trained and authorized personnel are allowed to repair (disassemble and reassemble) the FlowAct in haz­ardous areas.
Actuators for oil and grease-less service or oxygen service may only be disassembled and reassembled in clean rooms (ISO 14644- ISO 8, US FED STD 209 E - M 6.5, or equivalent).
max
with
top mounted
hand wheel
WARNING
Diaphragm linear actuators are pressure vessels. Improper opening of the actuator can result in bodily injury.
Actuator assembly procedure
1. Fix the valve on the assembly table.
NOTICE
mounting position !
2. Lubricate all threads with a suitable, approved lubri­cant (see Section 16).
3. Mount the actuator / yoke and yoke lock nut (76) onto the valve bonnet.
4. Finger tighten and fix the yoke lock nut; turn clockwise (see Section 15).
NOTICE
The orientation of the valve must be in accordance with the appropriate
The legs of the yoke should be paral­lel to the flow direction !
14. The valve is ready for the mounting of the accessories.
Actuator
344
249
240
76
345
113
5. If the fail safe position at air failure moves the stem into closing position then must the actuator connected with the air supply to move the stem into the open (retracted) position (in most cases).
WARNING
tween the yoke legs while the valve is in operation.
6. Mount the lock nut (113) and lower coupling (345) onto the valve stem.
7. Justify the plug against the seat.
8. Adjust the distance between the lower coupling (345) ant the upper coupling (249) with the aid of an adapter in stroke height (Figure 7).
9. Disconnect the air supply so that the actuator moves to the close position.
10. Mount the cap screws (240).
11. Lock the lock nut (113). Secure the upper coupling (249) against turn unwanted with a wrench.
Due to risk of crushing hazard, do not work be-
Valve
Figure 6: Yoke assembly drawing
Item
WW
76 5.10 Yoke lock nut 249 5.3 Upper coupling 113 5.2 Lock nut 344 5.4 Lock nut 240 5.5 Cap screw 345 5.1 Lower coupling
Part
EU
Table 4: Coupling parts identification
Item
WW EU
Part
12. Adjust the stroke indicator scale so that the zero mark is in conjunction with the stroke indicator.
13. Perform three full strokes and check if the stroke indi­cator scale correspond with the end positions.
Stroke
Figure 7: Stroke adjusting
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Reassemble the valve into the pipe
1. Remove the protective flange covers and coating from the control valve; clean the flange gasket surface.
NOTICE
graphite gaskets. Review a current chemical resis­tance list before applying.
Unsuitable cleaning agents can dam­age and cause leakage in PTFE and
11 Valve Quick-Check
Apply appropriate personal protective equip­ment when working on the control valve to prevent hazards arising from the operation. Protect yourself against freezing, burns and cuts by wearing appropriate protective cloth­ing, gloves and eye protection.
2. Install the valve so that the actuator is in an upright po­sition whenever possible. Vertical installation permits easier actuator maintenance.
3. Install and connect the control valve to the pipeline. Locate gaskets in the center of the body flanges and secure nuts and bolts.
4. Connect the air supply and instrument signal lines.
Do not over-tighten packing.
Sudden exposure of the control valve to full working pressure and temperature may cause stress cracks.
Prior to valve operation, we require, that you check the following conditions to reduce the risk of malfunction and safety related incidents.
No. Important information Possible malfunction or safety related incident
1
Avoid critical operating conditions where excessive noise or vibration levels might occur.
2
Avoid frequent system start-ups and shutdowns. Critical operating conditions, which can damage the
3
Keep the operating medium free of foreign particles. Installing a suitable strainer upstream of the control valve
4
Instrument air must conform to ISA 7.0.01-1996 (with a dew point at least 18 °F (10 °C) below ambient temperature, par­ticle size below 1 µm and oil content not to exceed 1 ppm)
5
6
Do not touch the body and bonnet ! The tempera­ture of the operating medium is transferred to the
surface of the linear actuator.
Critical operating conditions can cause exces­sive or hazardous levels of vibration or noise.
Impermissible continuous operation of a control valve under critical conditions can damage the valve.
control valve, may be encountered during system start-up or shut down.
can prevent foreign particles from damaging the valve.
Contaminated instrument air can damage the accessories and diaphragm linear actuator or cause them to fail.
Excessive hot surface temperatures can put you at risk for burns.
Frigid surface temperatures can put you at risk for freezing.
Impermissible levels of vibration can cause hearing loss, vascular and nerve damage and damage to joints and bones. Use hearing protection when noise levels exceed 80 dB(A).
10
7
Incorrect maintenance can result in the emission of hot, cryogenic, and / or toxic operating media.
Table 5: Basic safety massages for operating the valve
Incorrect maintenance can put you at risk for heat related burns, freezing, acid burns or poisoning.
WARNING
while the valve is in operation.
Prior to start-up, we strongly recommend that you:
1. Stroke the valve and compare the plug position indicator on the stem clamp to the stroke indicator plate. The plug should change position in a smooth, linear fashion.
NOTICE
such as PTFE. If over tightened, excessive friction may impair smooth control.
2. Adjust instrument signals to ensure a full stroke.
Due to risk of crushing hazard, do not work between the yoke legs
Graphite packing commonly creates more friction than other materials,
12 Actuator Maintenance
Maintenance intervals and service life of an actuator is unique to local environmental conditions at the site. The intervals specified in the User Instructions are recommendations and serve only as a guide. Under difficult operating conditions, maintenance may be more frequent. We strongly recom-
3. Check the packing box bolting to ensure the correct adjustment.
NOTICE
that may impede plug movement.
4. Continuously increase load until operation parameters are reached.
5. Minor relaxation of the flange bolting is possible after initial assembly. Retorque the bonnet flange bolting if necessary before installation or following an initial temperature excursion to ensure the bonnet gaskets do not leak.
(See User Instructions - Control Valve).
mend a site survey followed by a documented procedure for performing the maintenance work. Maintenance personnel should perform and log the work accordingly. The data col­lected can be used as a basis for dynamically determining the maintenance intervals and activities.
Over tightening can cause excessive packing wear and high stem friction
Recommended Maintenance Actions
No.
1 Visual inspection of
2 Visual inspection of
3 Visual inspection of
4 Operation test
Recommended maintenance actions using the Logix digital positioner with ValveSight diagnostic solution software
5 Visual inspection of
diagnostic interface
6 Check health parameter
of actuator
7 Check health parameter
of positioner
Service
the actuator
the tightness Preventive maintenance
of the diaphragm
case bolting
Inter-
val
Bi-
weekly
Bi-
weekly
Yearly No action Retighten case bolting if
Weekly No action -
Warn-
ing
Warn-
ing
Good Adequate Inadequate
No action Clean actuator stem with a
soft cloth
No action Retighten leaky air supply,
case bolting
Dependent upon results of previous maintenance (see numbers 1 and 2 above) or a minimum of once every 10 years
diaphragm leaks.
No action Perform 3 full strokes using air supply; check for leakage
Take action per warning Overhaul or replace required part per
valve is healthy No action -
actuator is healthy
No action ­positioner healthy
is
Check and retighten air supply
Start step test Overhaul or replace positioner after
Valve Condition
Repair or replace actuator according to product life cycle
Replace leaky air supply, diaphragm, O-ring immediately
Remove from service and replace case bolting, diaphragm immedi­ately if external leakage persists or if bolting is damaged
alarm Overhaul or replace actuator after
alarm
alarm
Table 6: Service activities check list
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Prior to valve maintenance it is required that you check the following conditions to reduce the risk of malfunction and safety related incidents.
No.
1 Check for signs of leakage through the case bolting
and end flanges.
2 Check if all nuts and bolts are securely fastened.
3 Check valve for smooth, full-stroke operation. Un-
steady stem movement could indicate an internal valve problem.
WARNING
from all moving parts when operating the control valve can cause serious injury.
1. Clear all dirt and / or foreign material from the shaft and control valve.
2. If leakage is detected, retighten the bolting.
3. Activities on the valve, see separate document.
Check Possible malfunction or safety related incident
Table 7: Basic safety massages for maintenance the valve
Crushing hazard ! Failure to keep hands, hair, and clothing away
Tighten the case bolting nuts. See Section 14: Disassembly and Reassembly for instructions. Also see Section 15.
Avoid critical operating conditions if excess noise or vibration levels occur during operation.
Internal valve failure requires an immediate overhaul or actua­tor replacement by qualified stuff.
6. Make sure all accessory brackets and bolting are securely fastened.
7. Check control valve health parameters:
• Characteristic curves of the valve with flow
• Upstream pressure
• Downstream pressure
4. Make sure all nuts and bolts are securely fastened.
5. If possible, stroke the valve and check for smooth, full-stroke operation. Unsteady stem movement could indicate an internal valve problem.
into the control room.
NOTICE
differ by more than 5%, maintenance may be required.
Monitor trim and bonnet compo­nents. If nominal and actual values
13 Troubleshooting
Contact customer service department or contract partner for any fault or defect found, otherwise the manufacturer‘s guarantee shall be rendered null and void and the manufacturer released from any responsibility. If the user performs the repairs, these User Instructions must be adhered to and carried out in a competent manner. Original Equipment Manufacturer spare parts must be used to make the repair.
Defect No. Possible Causes Remedy
Stem does not move 1.1 • No energy supply (pneumatic air)
to actuator and accessories (posi­tioner, air filter regulator, solenoid valve, limit switch, and/ or special accessories)
• Pneumatic actuators: Check supply for leaks Check air pressure (usually 6 bar; 88 psig)
12
1.2 • Mounted accessories do not work • See User Instructions for accessory manufacturer
1.3 • Pneumatic actuator is defective • Contact customer service department or contract partner
Defect No. Possible Causes Remedy
Jerky stem movement 2.1 • Damaged stem • Contact customer service department or contract
partner
2.2 • Actuator not powerful enough • Compare actuator specifications on the serial plate with operation specifications of the facility. If incompatible, contact customer service department or contract partner
Stem travel less than full stroke (0 to 100 %)
No limit switch signal 4.1 • Power supply to limit switch
Unstable positioner 5.1 • Defective positioner • See user instruction of the positioner manufacturer
14 Operation of the handwheel
WARNING
during regular operation. Actuation is only permitted with separated air supply !
1. The handwheel is always in the neutral position in the delivery condition.
2. The handwheel are designed to act against the fail safety position of the actuator. That means in the case of an pneumatic actuator design with restoring springs.
3.1 • Air supply pressure too low • Provide air at the pressure stated on the serial plate (European production only).
3.2 • Pneumatic actuators:
Improper handwheel position
3.3 • Improperly adjusted or defective
positioner
3.4 • Foreign particles in valve seat or
damaged trim
interrupted
4.2 • Limit switch out of adjustment • Readjust limit switch operating distance; see limit
Table 8: Trouble-shooting
Due to risk of crushing hazard, do not work with the handwheel
3. All handwheel designs are immediately ready for use,
4. Check the progress of the stroke adjustment on the
5. If normal operation is to be resumed, the handwheel
• Move handwheel to limit position , otherwise contact factory for information.
• Readjust positioner to positioner manufacturer‘s specification
• Contact customer service department or contract partner
• Check power supply (connections, circuit breakers, voltage)
switch data sheet
NOTICE
out the actuator the handwheel has no function.
except the lateral handwheel for the 1502 and 3002 actuator. In the event of fail safe position - spring-to-
open (retracted) - before using, the handwheel must turned counterclockwise up to contact the drive pin the coupling and subsequently locked.
stroke indicator scale.
must be turned always to the neutral position.
When adjusting, then the handwheel press against the spring force - with-
15 Disassembly and Reassembly
The FlowAct linear actuator is allowed to be disassembled and reassembled only by qualified staff
- personnel who are familiar with disassembling, reassembling, installation and commissioning of this product, and possess the relevant qualifications in their field of activity.
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When performing repairs, personnel are to follow these instructions using only original equipment manufacturer (OEM) spare parts and recommended special tools to ensure the reliability of the FlowAct linear actuator.
Only Flowserve trained and authorized personnel are allowed
WARNING
Prior to disassemble and reassemble, we require, that you check the following conditions to reduce the risk of malfunction and safety related incidents.
No. Important information Possible malfunction or safety related incident
1 Disregarding these instructions may bring serious or
harmful consequences.
2
Always observe system safety instructions when preparing for and performing the repair
procedure.
Pneumatic actuator are pressure vessels. Improper opening of the actuator can result in bodily injury.
to repair (disassemble and reassemble) the FlowAct in hazard areas.
Actuators and valves for oil and grease-less service or oxygen service only be disassembled and reassembled in clean rooms (ISO 14644- ISO 8, US FED STD 209 E - M 6.5, or equivalent).
Failure to comply with these user instructions will render the manufacturer‘s guarantee and liability null and void. Unless otherwise agreed, the manufacturer‘s general terms and conditions of sale shall apply.
Potential hazards and their sources are under the operator‘s influence. The operator must observe national and interna­tional environmental regulations for control valve removal from the pipe and cleaning. Permissible exposure limits must be maintained, appropriate personal protective equip­ment must be used and service personnel must be properly instructed in performing the repair procedure.
3 Make sure the pipeline is depressurized an in
ambient state, also a suitable rigging (e.g. Endless Sling) and securing devices (e.g. Vee Trough with Stands / Vise) are readily available.
4 Confirm that you have the required spare parts at the site. Not having the full complement of parts, accessories and
5
6 Review the serial plate information to identify the actua-
7 Check all parts for damage such as scoring, deformities,
Confirm that you have the required tools avail-
able to manage the disassembly and reassembly (Special Tools on request !).
tor. The serial number and the part numbers needed are required when ordering spare parts.
corrosion or overexpansion.
Table 9: Basic safety massages for repairing the actuator
Remove the valve / actuator from the pipeline in a depres­surized and ambient state. Failure to do so can cause seri­ous personal injury. The control valve is not equipped with integral stands, therefore guard against the valve from tipping over. Bodily injuries can be the result. Use appropriate clamps, block­ing or other stabilizing support. Attachment to overhead crane can ensure stability.
tools can slow or stop repair work.
Improper tools and / or improper use of tools can result in personal injury or damage to the parts.
A serial plate used for product identification is attached on every valve / actuator (See Section 3: Product Identifica­tion).
If in doubt, replace faulty parts. Never reuse gaskets.
After these requirements are confirmed the pneumatic actuator can be maintained and repaired.
14
Disassemble the actuator from the valve:
WARNING
Improper opening of the actuator
can result in bodily injury.
1. Disconnect the air supply from the actuator and / or assembled accessories.
2. Disassemble the accessories from the actuator as nec­essary.
3. If is mounted a handwheel-side disassemble this first (see pages 37 - 38).
4. Realize the fail safe position of the actuator. The coupling parts must be free of positioning force.
Crushing hazard ! The
Actuators are pressure vessels.
WARNING
actuator stem is under spring load. Never disconnect the air supply during next steps, the stem will extends very quickly.
• If the actuator stem is extended, drive it into re-
tracted position by connecting air supply.
344
249
Actuator
240
76
345
113
Valve
• If the actuator stem is retracted no further action
is required.
• If the valve type is a three way valve drive the stem
into center position by connecting and control air supply.
5. Keep upper coupling (249) from turning by secure with a wrench. Turn the lock nut (113) clockwise to loosen.
6. Turn the cap screws (240) counterclockwise to loosen.
7. Turn the yoke lock nut (76) counterclockwise to loosen.
8. Disconnect the air supply from the actuator if appli­cable.
9. Lift off the actuator safely.
10. Place the actuator on an assembly table and fix the yoke for disassembly.
Figure 8: Yoke assembly drawing
Item
WW
76 5.10 Yoke lock nut 249 5.3 Upper coupling 113 5.2 Lock nut 344 5.4 Lock nut 240 5.5 Cap screw 345 5.1 Lower coupling
Part
EU
Table 10: Coupling parts identification
Item
WW EU
Part
The modular design of the actuators enables a wide variety of variants. Following therefore is always described the individual module and not the entire actuator. We ask for your understanding.
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15
Reassemble the Actuator onto the valve:
1. Mount the actuator onto the bonnet and tighten the yoke lock nut (76) clockwise.
The legs of the yoke should be parallel
NOTICE
to the flow direction.
2. Move the actuator to the open position.
3. Screw in the lock nut (113) onto the valve stem so it is screwed all the way and lower coupling (345) three turns and move the actuator into the closed position.
The plug must be aligned onto the
NOTICE
seat. The cushioning effect of the bel-
lows can be prevented by tightening the packing follower.
4. Move the actuator back into the open position and adjust the distance between the lower coupling (345) and upper coupling (249) by adjusting the stroke length.
Valve size Stroke
+ 0,5
15 - 25 1/2“ - 1“ 10
15 - 50 1/2“ - 2“ 20
65 - 100 3“ - 4“ 40
125 - 150 6“ 60
1)
200 - 300
8“ - 12“ 1)80
400 16“ 100
Table 11: Stroke adjustment length ( 1) depends on the valve
series)
mm 0.394
+ 0,5
mm 0.787
+ 0,5
mm 1.574
+ 0,8
mm 2.362
+ 0,8
mm 3.150
+ 0,8
mm 3.937
+ 0.02
+ 0.02
+ 0.02
+ 0.03
+ 0.03
+ 0.03
in.
in.
in.
in.
in.
in.
9. Check handwheel-side for correct limit position, if applicable.
10. Reassemble the accessory on the valve as necessary, see relevant accessory User Instruction.
11. Perform three full strokes and check the free movement of the actuator.
12. For installation the valve into the pipeline and further steps see User Instructions for applicable valve types.
13. Log the maintenance interval and the work performed.
Actuator
344
249
240
76
345
113
16
5. Move the actuator to the close position and install the cap screws (240).
6. Lock the lock nut (113). Keep upper coupling (249) from turning by securing with a wrench.
7. If a handwheel-side was mounted reassemble as next (see pages 37 - 38).
The handwheel-side always presses
NOTICE
on the coupling, depending on the safety position when actuated. The lever arms must be positioned so that this condition is given.
8. Place the handwheel-side on the yoke and straighten it, mount the washer (140) and hex bolt (150) and tighten it, if applicable.
Valve
Figure 9: Yoke assembly drawing
Item
WW
76 5.10 Yoke lock nut 249 5.3 Upper coupling 113 5.2 Lock nut 344 5.4 Lock nut 240 5.5 Cap screw 345 5.1 Lower coupling
Part
EU
Table 12: Coupling parts identification
Item
WW EU
Part
Pneumatic Actuator - Type 253, 503, 701
• Type 1502 see page 39
• Type 3002 see page 57
light-duty heavy-duty
see pages 26 - 27 see pages 28 - 31 see pages 32 - 33
Attachments
Handwheel Stroke Limitation
adjustable limit stop
Actuator without attachments Actuator with attachments
Spring-to-close Spring-to-open Spring-to-close Spring-to-open
see pages 18 - 19 see pages 20 - 21 see pages 22 - 23 see pages 24 - 25
Cast yoke design acc. to IEC 60534-6-1 Handwheel
NAMUR-yoke,
with double mounting pads
MULTI-yoke,
with pad and interface for
direct positioner and sole-
noid valve mounting
IAS-yoke,
with double pads and in-
terface for direct positioner
mounting
side-mounted
for IAS-yoke only
see page 34 see page 35 see page 36 see pages 37 - 38
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17
Actuator without attachments
Spring-to-close
Disassembly instruction of the actuator subas­sembly
NOTICE
1. Fix the actuator on the assembly table, if this is not already happened.
2. Loosen the lock nut (344) counterclockwise and disas­semble the upper coupling (249) and lock nut clock­wise (see page 15).
3. Disassemble the short hexagon bolts (335), plain wash­ers (337), hexagon nuts (351) and ring nuts (209).
4. Pull off the protection sleeve (339).
springs inside.
5. Lubricate the threads and loosen the long hexagon bolts (336), plain washers (337) and hexagon nuts (351) uni­formly in a clockwise sequence as the springs expand.
Limit disassembly only to necessary compo­nents.
WARNING
Risk of injury by jump­ing out parts ! Pre-loaded
Reassembly instruction of the actuator subas­sembly
NOTICE
13. Lubricate the new O-ring (275), new scraper ring (273) with an appropriate lubricant and install into the guide bushing (253).
14. Lubricate the new O-ring (272) with an appropriate lubricant.
15. Lower the thrust washer (255), diaphragm (225), O-
onto the stem (211).
16. Lubricate the thread of the stem (211) with an appro­priate lubricant and install and finger tighten the spe­cial nut (348).
NOTICE
of the Positioning Template. Mark the position.
Always replace parts showing wear with new parts.
ring (272), diaphragm plate (227), spacer bushing (228), lock washer (349)
The diaphragm plate should be posi­tioned to the diaphragm with the aid
18
NOTICE
8.8 or higher, as well as washers and nuts.
6. Lift off the diaphragm casing (203), distance plate (231) and spring adjusting plate (326).
7. Remove the actuator springs (229).
8. Carefully remove the diaphragm-stem unit (211 - 349).
9. Remove the scraper ring (273) and O-ring (275).
10. Secure the diaphragm-stem unit into the Special Tool.
11. Loosen the special nut (348) counterclockwise and remove the lock washer (349), spacer bushing (228), diaphragm plate (227), diaphragm (225), O-ring (272) and thrust washer (255).
12. Check stressed surface areas for damage such as scor­ing and deformities. Use a brass brush or similar tool to clean bolting. Check for corrosion or any other damage.
We recommend using threaded bolts meeting standards from ISO 898-1,
17. Turn the special nut (348) clockwise using a suitable torque wrench.
18. Loosen and remove the diaphragm-stem unit (211-
349) from the Special Tool. Lubricate the actuator stem with an appropriate lubricant.
19. Carefully lower the diaphragm-stem unit (211- 349) into the diaphragm casing.
NOTICE
Mark align.
20. Install and align the actuator springs (229).
21. Install and positioning the spring adjusting plate (326) such that the drilling, mark and air connection match.
22. Install the distance plate (231) and diaphragm casing (203), positioning the casing such that the drilling, mark and air connections match.
23. Lubricate the threats of the long hexagon bolts (336) with an appropriate lubricant then compress the springs
Position the diaphragm-stem unit such that the air connection and the
uniformly in a clockwise sequence by tightening the long hexagon bolts (336), plain washers (337) and hexagon nuts (351). Alternative method see NOTICE step 5.
24. Install the short hexagon bolts (335), hexagon nuts (351) as well as the hexagon bolts (335) and ring nuts (209).
25. Tighten the nuts (351) using a crosswise pattern in four steps.
26. Install the protection sleeve (339).
27. Reassemble the yoke and coupling parts, perform three full strokes then check the tightening of the casing bolting.
Item #
Part
WW EU
202 6.1 Diaphragm Casing
203 6.2 Diaphragm Casing
209 6.6 Ring Nut
211 6.12 Stem
225 6.16 Diaphragm
227 6.15 Diaphragm Plate
228 6.13 Spacer Bushing
229 6.21 Actuator Spring
231 6.22 Distance Plate
253 6.8 Guide Bushing
254 6.80 Plain Bearing
255 6.18 Thrust Washer
258 6.26 Vent Plug
272 6.17 O-Ring
273 6.11 Scraper Ring
275 6.10 O-Ring
326 6.23 Spring Adjusting Plate
335 6.3.1 Hexagon Bolt - short
336 6.3.2 Hexagon Bolt - long
337 6.5 Plain Washer
339 6.25 Protection Sleeve
348 6.20 Special Nut
349 6.19 Lock Washer
351 6.4 Hexagon Nut
28. Log the maintenance interval and the work performed.
29. The actuator subassembly is ready to be mounted on the valve and the accessories attached.
336
335
337
203 258
231
326
229
202 253 254
351
339
275
273
Table 13: Actuator parts
Figure 10: Actuator parts
19
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Actuator without attachments
Spring-to-open
Disassembly instruction of the actuator subas­sembly
NOTICE
1. Fix the actuator on the assembly table, if this is not already happened.
2. Loosen the lock nut (344) counterclockwise and disas­semble the upper coupling (249) and lock nut clock­wise (see page 15).
3. Disassemble the hexagon bolts (335), plain washers (337), hexagon nuts (351) and ring nuts (209).
4. Pull off the protection sleeve (339).
springs inside.
5. Lubricate the threads and loosen the long hexagon bolts (336), plain washers (337) and hexagon nuts (351) uni­formly in a clockwise sequence as the springs expand.
NOTICE
8.8 or higher, as well as washers and nuts.
6. Lift off the diaphragm casing (203).
Limit disassembly only to necessary compo­nents.
WARNING
We recommend using threaded bolts meeting standards from ISO 898-1,
Risk of injury by jump­ing out parts ! Pre-loaded
Reassembly instruction of the actuator subas­sembly
NOTICE
14. Lubricate the new O-ring (275), new scraper ring (273) with an appropriate lubricant and install into the guide bushing (253).
15. Lubricate the new O-ring (272) with an appropriate lubricant.
16. Lower the spacer bushing (228), diaphragm plate
onto the stem (211).
17. Lubricate the thread of the stem (211) with an appro­priate lubricant and install and finger tighten the spe­cial nut (348).
18. Turn the special nut (348) clockwise using a suitable torque wrench.
19. Loosen and remove the diaphragm-stem unit (211-
349) from the Special Tool. Lubricate the actuator stem with an appropriate lubricant.
20. Install and positioning the spring adjusting plate (326) such that the drilling and air connection match.
Always replace parts showing wear with new parts.
(227), diaphragm (225), O-ring (272), thrust washer (255), lock washer (349)
20
7. Carefully remove the diaphragm-stem unit (211 - 349).
8. Remove the actuator springs (229).
9. Remove the spring adjusting plate (326).
10. Remove the scraper ring (273) and O-ring (275).
11. Secure the diaphragm-stem unit into the Special Tool.
12. Loosen the special nut (348) counterclockwise and remove the lock washer (349), thrust washer (255), O­ring (272), diaphragm (225), diaphragm plate (227), and spacer bushing (228).
13. Check stressed surface areas for damage such as scoring and deformities. Use a brass brush or similar tool to clean bolting. Check for corrosion or any other damage.
21. Install and align the actuator springs (229).
22. Carefully lower the diaphragm-stem unit (211- 349) into the diaphragm casing.
23. Install the diaphragm casing (203), positioning the casing such that the air connections are aligned.
24. Lubricate the threats of the long hexagon bolts (336) with an appropriate lubricant then compress the springs uniformly in a clockwise sequence by tightening the long hexagon bolts (336), plain washers (337) and hexagon nuts (351). Alternative method see NOTICE step 5.
25. Install the short hexagon bolts (335), hexagon nuts (351) as well as the hexagon bolts (335) and ring nuts (209).
26. Tighten the nuts (351) using a crosswise pattern in four steps.
27. Install the protection sleeve (339).
28. Reassemble the yoke and coupling parts, perform three full strokes then check the tightening of the casing bolting.
29. Log the maintenance interval and the work performed.
30. The actuator subassembly is ready to be mounted on the valve and the accessories attached.
Item #
Part
WW EU
202 6.1 Diaphragm Casing
203 6.2 Diaphragm Casing
209 6.6 Ring Nut
211 6.12 Stem
225 6.16 Diaphragm
227 6.15 Diaphragm Plate
228 6.13 Spacer Bushing
229 6.21 Actuator Spring
253 6.8 Guide Bushing
254 6.80 Plain Bearing
255 6.18 Thrust Washer
258 6.26 Vent Plug
272 6.17 O-Ring
273 6.11 Scraper Ring
275 6.10 O-Ring
326 6.23 Spring Adjusting Plate
335 6.3.1 Hexagon Bolt - short
336 6.3.2 Hexagon Bolt - long
337 6.5 Plain Washer
339 6.25 Protection Sleeve
348 6.20 Special Nut
349 6.19 Lock Washer
351 6.4 Hexagon Nut
209
348
349
255
225
227
228
211
336
335
337
203
272
229
326
202 253 254 258
351
339
275
273
Table 14: Actuator parts
Figure 11: Actuator parts
21
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Actuator with attachments
Spring-to-close
Disassembly instruction of the actuator subas­sembly
NOTICE
1. Fix the actuator on the assembly table, if this is not already happened.
2. Disassemble the attachments first (see page 16).
3. Loosen the lock nut (344) clockwise and disassemble the upper coupling (249) and lock nut (see page 15).
4. Disassemble the hexagon bolts (335), plain washers (337), hexagon nuts (351) and ring nuts (209).
5. Pull off the protection sleeve (339).
springs inside.
6. Lubricate the threads and loosen the long hexagon bolts (336), plain washers (337) and hexagon nuts (351) uni­formly in a clockwise sequence as the springs expand.
Limit disassembly only to necessary compo­nents.
WARNING
Risk of injury by jump­ing out parts ! Pre-loaded
Reassembly instruction of the actuator subas­sembly
NOTICE
14. Lubricate the new O-rings (275), new scraper rings (273) with an appropriate lubricant and install into the guide bushing (253 and 390).
15. Lubricate the new O-ring (272) with an appropriate lubricant.
16. Lower the thrust washer (255), diaphragm (225), O-
onto the stem (211).
17. Lubricate the thread of the stem (211) with an appropriate lu­bricant and install and finger tighten the special stem (348).
NOTICE
of the Positioning Template. Mark the position.
18. Turn clockwise the special stem (348) using a suitable torque wrench.
Always replace parts showing wear with new parts.
ring (272), diaphragm plate (227), spacer bushing (228), lock washer (349)
The diaphragm plate should be posi­tioned to the diaphragm with the aid
22
NOTICE
8.8 or higher, as well as washers and nuts.
7. Lift off the diaphragm casing (203) and spring adjust­ing plate (326).
8. Remove the actuator springs (229).
9. Carefully remove the diaphragm-stem unit (211 - 349).
10. Remove the scraper rings (273) and O-rings (275).
11. Secure the diaphragm-stem unit into the Special Tool.
12. Loosen the special stem (348) counterclockwise and remove the lock washer (349), spacer bushing (228), diaphragm plate (227), diaphragm (225), O-ring (272) and thrust washer (255).
13. Check stressed surface areas for damage such as scoring and deformities. Use a brass brush or similar tool to clean bolting. Check for corrosion or any other damage.
We recommend using threaded bolts meeting standards from ISO 898-1,
19. Loosen and remove the diaphragm-stem unit (211
- 349) from the Special Tool. Lubricate the actuator stems with an appropriate lubricant.
20. Carefully lower the diaphragm-stem unit (211 - 349) into the diaphragm casing.
NOTICE
Mark align.
21. Install and align the actuator springs (229).
22. Install and positioning the spring adjusting plate (326) such that the drilling, mark and air connection match.
23. Install the diaphragm casing (203), positioning the casing such that the drilling, mark and air connections match.
24. Lubricate the threats of the long hexagon bolts (336) with an appropriate lubricant and load the springs uni­formly in a clockwise sequence by tightening the long hexagon bolts (336), plain washers (337) and hexagon nuts (351). Alternative method see NOTICE step 6.
Position the diaphragm-stem unit such that the air connection and the
25. Install the short hexagon bolts (335), hexagon nuts (351) as well as the hexagon bolts (335) and ring nuts (209).
26. Tighten the nuts (351) using a crosswise pattern in four steps.
27. Install the protection sleeve (339).
28. Reassemble the yoke and coupling parts, perform three full strokes then check the tightening of the casing bolting.
Item #
Part
WW EU
202 6.1 Diaphragm Casing
203 6.2 Diaphragm Casing
209 6.6 Ring Nut
211 6.12 Stem
225 6.16 Diaphragm
227 6.15 Diaphragm Plate
228 6.13 Spacer Bushing
229 6.21 Actuator Spring
231 6.22 Distance Plate
253 6.8 Guide Bushing
254 6.80 Plain Bearing (2x)
255 6.18 Thrust Washer
258 6.26 Vent Plug
272 6.17 O-Ring
273 6.11 Scraper Ring (2x)
275 6.10 O-Ring (2x)
276 6.9 O-Ring
326 6.23 Spring Adjusting Plate
335 6.3.1 Hexagon Bolt - short
336 6.3.2 Hexagon Bolt - long
337 6.5 Plain Washer
339 6.25 Protection Sleeve
348 6.29 Stem
349 6.19 Lock Washer
351 6.4 Hexagon Nut
390 6.24 Guide Bushing
29. Log the maintenance interval and the work performed.
30. The actuator subassembly is ready for the reassemble of the attachments - see page 16 - and accessories.
336
335
337
202
276
390 254
258
326
229
202
276
253 254
351
339
275
273
Table 15: Actuator parts
Figure 12: Actuator parts
23
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