Flowserve LHS Hydraulic Heavy-Duty Actuator Series User Manual

USER INSTRUCTIONS

LHS Hydraulic Heavy-Duty Actuator Series

Single Acting & Double Acting

LFENIM0003-00-AQ – 07/14

Installation

Operation

Maintenance

Experience In Motion

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Contents

1. Standard Information 3

1.1 General Usage 3

1.2 Terms Concerning Safety 3

1.3 Protective Clothing 3

1.4 Qualiﬁed Personnel 4

1.5 Other General Requirements for In-Plant Installation 4

1.6 Spare Parts 4

1.7 Service/Repair 4

1.8 Actuator Lifting and Handling 4

1.9 Storage 6

1.10 Valve and Actuator Variations 7

1.11 Unpacking 7

2 Installation Instructions 8

2.1 Valve and Actuator Check 8

2.2 Connection With Valve and Mounting Kit 9

2.3 Travel Stop Bolts and Accessories 10

2.4 Grounding System 10

2.5 Hydraulic Supply Pressure 11

2.6 Initial Operation 11

2.7 Fail Open and Fail Close Conﬁguration 12

3 Field Conversion 13

3.1 Actuator Disassembled From the Valve 13

3.2 Actuator Connected to the Valve (and the valve can be stroked) 14

4. Maintenance Instructions 16

4.1 General Disassembly Instructions 16

4.2 Spring Container Maintenance 17

4.3 Hydraulic Cylinder Maintenance 18

4.4 Scotch Yoke Housing Maintenance 19 5 Troubleshooting 20 6 Disposal of Decommissioned Actuators 22 7 Annex 23

Figures

Figure 1: Eyebolts for the Lifting 5 Figure 2: Handling of the Double Acting Actuator 5 Figure 3: Vent Valve Position 5 Figure 4: Single Acting Actuator Lifting System 5 Figure 5: Correct Lifting System 6 Figure 6: Actuator’s Position on Wooden Pallet 6 Figure 7: Standard Nameplate Position 8 Figure 8: Nameplate Sample 8 Figure 9: Grounding Kit Assembled 10 Figure 10: Grounding Kit – Exploded View 10 Figure 11: Grounding Kit 10 Figure 12: Single Acting Actuator Conﬁguration: Fail Close – Fail Clockwise 12 Figure 13: Single Acting Actuator Conﬁguration: Fail Open – Fail Counter Clockwise 12 Figure 14: Double Acting Actuator Conﬁguration – Close Position 12 Figure 15: Double Acting Actuator Conﬁguration – Open Position 12 Figure 16: Single Acting LHS – Fail Close Conﬁguration With Valve 12 Figure 17: Double Acting LHS With Valve 12 Figure 18: Single Acting Actuator 16 Figure 19: Spring Can Exploded View 17 Figure 20: Exploded View of Hydraulic Cylinder 18 Figure 21: Exploded View of Adaptor Kit 19

Figure 22: Exploded View of Housing 19 Figure 23: LHS Model Selection Table 23 Figure 24: Weight Selection Table – Double Acting Models 23 Figure 25: Weight Selection Table – Single Acting Models 23

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Standard Information

1.1 General Usage

The following instructions are designed to assist in unpacking, installing and performing maintenance as required on Flowserve products. Product users and maintenance personnel should thoroughly review this bulletin prior to installing, operating or performing any maintenance.

In most cases Flowserve actuators and accessories are designed for speciﬁc applications with regard to medium, pressure and temperature. For this reason they should not be used in other applications without ﬁrst contacting the manufacturer.

1.2 Terms Concerning Safety

The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instructions to highlight particular dangers and/or to provide additional information on aspects that may not be readily apparent.

DANGER: indicates that death, severe personal injury and/or substantial property damage will occur if proper

precautions are not taken.

a WARNING: indicates that death, severe personal injury and/or substantial property damage can occur if proper

precautions are not taken.

a CAUTION: indicates that minor personal injury and/or property damage can occur if proper precautions are not

taken.

NOTE: indicates and provides additional technical information, which may not be very obvious, even to qualiﬁed personnel.

Compliance with other, not particularly emphasized notes, with regard to transport, assembly, operation and maintenance and with regard to technical documentation (e.g. in the operating instruction, product documentation or on the product itself) is essential, in order to avoid faults, which in themselves might directly or indirectly cause severe personal injury or property damage.

1.3 Protective Clothing

Flowserve products are often used in problematic applications (e.g. extremely high pressures, dangerous, toxic or corrosive media). When performing service, inspection or repair operations always ensure, that the valve and actuator are depressurized and that the valve has been cleaned and is free from harmful substances. In such cases pay particular attention to personal protection (protective clothing, gloves, glasses etc.).

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

1.4 Qualiﬁed Personnel

Qualiﬁed personnel are people who, on account of their training, experience and instruction and their knowledge of relevant standards, speciﬁcations, accident prevention regulations and operating conditions, have been authorized by those responsible for the safety of the plant to perform the necessary work and who can recognize and avoid possible dangers.

1.5 Other General Requirements for In-Plant Installation

• Pipelines must be correctly aligned to ensure that the valve is not ﬁtted under tension.

• Flowserve can provide ﬁre protection system. If not expressly agreed, ﬁre protection must be provided by user.

1.6 Spare Parts

Use only Flowserve original spare parts. Flowserve cannot accept responsibility for any damages that occur from using spare parts or fastening materials from other manufacturers. If Flowserve products (especially sealing materials) have been stored for long periods (more than 4 months to two years) check these for corrosion or deterioration before using these products.

1.7 Service/Repair

To avoid possible injury to personnel or damage to products, safety terms must be strictly adhered to. Modifying this product, substituting non-factory parts, or using maintenance procedures other than outlined in this instruction could drastically affect performance and be hazardous to personnel and equipment, and may void existing warranties. Between actuator and valve there are moving parts. To avoid injury Flowserve provides pinch-point-protection in the form of cover plates, especially where side-mounted positioners are ﬁtted. These protections are according to Machine Directive 2006/42/EC recommendations. If these plates are removed for inspection, service or repair special attention is required. After completing work the cover plates must be reﬁtted.

Apart from the operating instructions and the obligatory accident prevention directives valid in the country of use, all recognized regulations for safety and good engineering practices must be followed.

a WARNING: Before products are returned to Flowserve for repair or service, Flowserve must be provided with

a certiﬁcate which conﬁrms that the product has been decontaminated and is clean. Flowserve will not accept deliveries if a certiﬁcate has not been provided (a form can be obtained from Flowserve).

1.8 Actuator Lifting and Handling

Only Allen wrenches and hexagonal wrenches of the correct size are required for overall maintenance operations. The lifting equipment consists on commercial chains and slings of adequate dimensions.

In order to prevent any damage to actuator accessories and actuator control panel, before starting the lifting operations,

check that the lifting tools are away from them and avoid any interference between them.

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

a CAUTION: The actuator lifting and handling should be made by qualiﬁed staff and in compliance with the laws and

provisions in force.

a WARNING: The lifting lugs are appropriate for actuator lifting alone and not for the valve and actuator assembly

lifting. Avoid that during the handling, the actuator passes above the staff. The actuator should be handled with appropriate lifting means. The weight of the actuator is reported on the packing slip and on overall-dimensions drawings furnished with the documents accompanying the actuator.

For actuator weight, refer to Figures 24 and 25 in Annex section. For the general actuator dimensions, refer to LHS technical bulletin LFENTB0003, available on www.ﬂowserve.com.

NOTE: For lifting and handling, use the eyebolts on the

housing. The eyebolt on the spring can (for single acting version) is only for the mounting/dismounting steps or eventually for balancing the actuator.

Figure 1: Eyebolts for the Lifting

Figure 2: Handling of the Double Acting Actuator

a WARNING: Only for actuator balancing or spring

container mounting/dismounting operation

Figure 3: Vent Valve Position

CENTER OF MASS

Figure 4: Single Acting Actuator Lifting System

EYEBOLTS FOR ACTUATOR LIFTING

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Figure 5: Correct Lifting System

a WARNING: For actuator lifting and handling use the appropriate lifting eyebolts installed on the scotch-yoke

housing, as shown in Figures 4 and 5.

1.9 Storage

In many cases Flowserve products are manufactured from stainless steel. Products not manufactured from stainless steel are typically provided with an epoxy resin coating or with other painting systems agreed with the customer. This means that Flowserve products are well protected from corrosion. Nevertheless, in order to maintain good working conditions and a good ﬁnish until the actuator is installed on the plant, it is necessary to follow a few rules during the storage period:

• Flowserve products must be stored adequately in a clean, dry environment.

• Ensure that plastic caps are ﬁtted to protect the hydraulic connections and the cable entries, to prevent the ingress

of foreign materials. These caps should not be removed until the product is actually mounted into the system.

• If the storage is outdoor, or if long-term

storage (more than 4 months) is necessary, the plastic protection plugs have to be replaced by metal plugs, because the plastic plugs are not weather-proof function, whereas the metal ones guarantee a weatherproof protection.

• The actuator must be placed on a wooden

pallet, in order to not damage the coupling base and avoid that other surfaces rest on the ground.

Figure 6: Actuator’s Position on Wooden Pallet

LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

In case of long-term storage (more than 4 months), additionally perform the following measures:

• Coat the coupling parts (spool piece base, ﬂanges, bushings, joints) with protective oil or grease.

• If possible, blank off the spool piece base ﬂange by a protection disk.

• Provide a tarpaulin cover or some other means of protection, especially if the storage is outdoor.

• It is important to periodically operate the actuator

1.10 Valve and Actuator Variations

These instructions cannot claim to cover all details of all possible product variations, nor can they provide information for every possible example of installation, operation or maintenance. This means that the instructions normally include only the directions to be followed by qualiﬁed personnel where the product is being used for its deﬁned purpose. If there are any uncertainties in this respect particularly in the event of missing product-related information, clariﬁcation must be obtained via the appropriate Flowserve sales ofﬁce.

1.11 Unpacking

• Each delivery includes a packing slip. When unpacking, check all delivered actuators and accessories using this

packing slip.

• Report transport damage to the carrier immediately.

• In case of discrepancies, contact your nearest Flowserve location.

• If necessary, retouch minor damage to the paint coating which may have occurred during transport or storage.

NOTE: When the actuator has ATEX or SIL requirements, ensure that the “LHS Series Safety Manual” (Functional Safety and SIL Certiﬁcation) and “LHS Series Safety Extract and Instruction Manual” (Explosive Atmosphere Equipment and ATEX Certiﬁcation) accompany this manual and are referred to for equipment usage.

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LHS Hydraulic Heavy-Duty Actuator Series FCD LFENIM0003-00-AQ 7/14

Installation Instructions

The LHS is a fully modular design scotch-yoke actuator, with mounting base in compliance with ISO 5211 and the Technical Bulletin (LFENTB0003-00). It may also be customized, if required.

The LHS Hydraulic Scotch Yoke Spring Return Actuators adopt a push-to-compress spring design.

a WARNING: Actuator operation/pressure limitations must be in accordance with Technical Bulletin (LFENTB0003-00)

2.1 Valve and Actuator Check

DANGER: Before installation check the order no., serial no., and/or the tag no. to ensure that the valve/actuator is

correct for the intended application.

Figure 7: Standard Nameplate Position

Figure 8: Nameplate Sample

Prior to mounting the actuator to the valve, manually open and close the valve (if possible) to ensure it is not stuck. Be sure valve and Limitorque actuator rotate in the same direction and are in the same position (i.e.: valve closed, actuator closed). The assembly position of the actuator, with reference to the valve, has to be in accordance with the plant requirements (actuator axis parallel or perpendicular to the pipeline axis).

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