Flowserve Mechanical User Manual

USER INSTRUCTIONS

Mechanical and Hydraulic Manual Overrides

FCD LFENIM0004-00-AQ – (05/15)

Installation

Operation

Maintenance

Experience In Motion

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

Contents

1 Standard Information 4

1.1 Using Flowserve Valves, Actuators & Accessories Correctly 4

1.2 Terms Concerning Safety 4

1.3 Protective Clothing 4

1.4 Qualified Personnel 5

1.5 Other General Requirements for In-Plant Installation 5

1.6 Spare Parts 5

1.7 Service/Repair 5

1.8 Storage 6

1.9 Valve and Actuator Variations 6

1.10 Unpacking 6

2 Mechanical Manual 7

2.1 Enclosed Jackscrew Manual Override (-JS) 7

2.1.1 Installation 8

2.1.2 Operation – Enclosed Jackscrew Override
Installed on Single-Acting Actuator 8

2.1.3 Operation – Enclosed Jackscrew Override
Installed on Double-Acting Actuator 9

2.2 Not Enclosed Jackscrew Manual Override (-JL) 9

2.2.1 Installation 11

2.2.2 Operation – Not Enclosed Jackscrew Override
Installed on LPS/LPC Single-Acting Actuator 12

2.2.3 Operation – Not Enclosed Jackscrew Override
Installed on Double-Acting LPC Actuator 13

2.3 Bevel Gear Manual Overrides (-BG) 14

2.3.1 Installation 14

2.3.2 Operation – Bevel Gear Override Installed on
LPS Single-Acting Actuator 15

3 Hydraulic Manual Overrides 16

3.1 Hydraulic Hand Pump Manual Override (-HP) 16

3.1.1 Installation 17

3.1.2 Operation – Hydraulic Hand Pump Override
Installed on LPS Single-Acting Actuator 17

3.1.3 Operation – Hydraulic Hand Pump Override
Installed on LPS Double-Acting Actuator 19

3.1.4. Operation – Hydraulic Hand Pump Override
Installed on LHS Single Acting Actuator 21

3.1.5 Operation – Hydraulic Hand Pump Override
Installed on LHS Double-Acting Actuator 22

4 Maintenance Instructions 24

2

4.1 Service Kits 25

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

Figures

Figure 1 – Enclosed Jackscrew Manual Override for Double-Acting
Actuators (left) and for Single-Acting Actuators (right) 7
Figure 2 – LPS Single-Acting with Enclosed Jackscrew Override 8
Figure 3 – LPS Double-Acting with Enclosed Jackscrew
Override (declutchable) 9
Figure 4 – Detail of LPS Double-Acting with Enclosed
Jackscrew Override (declutchable) 10
Figure 5 – Not Enclosed Jackscrew Manual Override 11
Figure 6 – LPS/LPC Single-Acting with Not Enclosed
Jackscrew Override 12
Figure 7 – LPC Double-Acting with Not Enclosed
Jackscrew Override 13
Figure 8 – Bevel Gear Manual Override 14
Figure 9 – LPS Single-Acting with Bevel Gear Override 15
Figure 10 – Hydraulic Hand Pump Manual Override 16
Figure 11 – Hydraulic Hand Pump Manual Override Installed
on Single-Acting actuator 17
Figure 12 – Hydraulic Diagram LPS Single-Acting Actuator
with Hydraulic Override 18
Figure 13 – Details of Hydraulic Hand Pump Manual Override
for Single-Acting Actuator 19
Figure 14 – Hydraulic Hand Pump Manual Override Installed
on Double-Acting Actuator 19
Figure 15 – Hydraulic Diagram of LPS Double-Acting Actuator
with Hydraulic Override 20
Figure 16 – Details of Hydraulic Hand Pump Manual Override
for Double-Acting Actuator 20
Figure 17 – Hydraulic Hand Pump Manual Override Installed
on LHS Single Acting Actuator 21
Figure 18 – Hydraulic Diagram of Manual Override for
LHS Single Acting 22
Figure 19 – Hydraulic Hand Pump Manual Override
installed on LHS Single Acting Actuator 22
Figure 20 – Hydraulic Diagram of Manual Override
for LHS Double Acting 23
Figure 21 – Detail of Not-Enclosed Jackscrew and
Hand Pump Assembly 24

Tables

Table 1 – Spare Parts of Enclosed Jack Screw Manual Override
Installed on Single-Acting Actuator 25
Table 2 – Spare Parts of Enclosed Jack Screw (declutchable)
Manual Override Installed on Double-Acting Actuator 25
Table 3 – Spare Parts of Not Enclosed Jack Screw
Manual Override 26
Table 4 – Spare Parts of Bevel Gear Manual Override 26
Table 5 – Spare Parts of Hydraulic Manual Override:
Hydraulic Cylinder Assembly 27
Table 6 – Spare Parts of Hydraulic Manual Override:
Hydraulic Pump Assembly 27

flowserve.com

3

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

Standard Information

1

1.1 Using Flowserve Valves, Actuators and Accessories Correctly

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

In most cases Flowserve mechanical and hydraulic overrides are designed for specific applications with regard to pressure, tempera­ture and media. For this reason they should not be used in other applications without first contacting the manufacturer. This manual
shall be used in conjunction with any other instruction, document, checklist with the actuator the accessories are installed onto, also
related to single equipment or parts of actuator itself.

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

c

taken.

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

not taken.

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 obvious, even to qualified
personnel.

Compliance with all other notes regarding 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 conditions or
occurrences which might directly or indirectly cause severe personal injury or property damage.

1.3 Protective Clothing

Flowserve products are often used in dangerous applications (e.g., extremely high pressures, flammable, combustible, 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

4

personal protection equipment (protective clothing, gloves, glasses, etc.).

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

1.4 Qualified Personnel

Only Qualified Personnel should perform installation, operation or maintenance activities. Qualified personnel are people who, because
of their training, experience, 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 and its employees 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.

• If not expressly agreed, fire protection is not supplied along with the actuator, and it must be provided by user.

1.6 Spare Parts

Use only Flowserve brand 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), check for corrosion or deterioration before using these products.

1.7 Service/Repair

To avoid injury to personnel or damage to products, safety terms must be strictly adhered to. Modifying this product, substituting
non-OEM 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.

In addition to 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).

flowserve.com

5

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

1.8 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 and its
accessories are installed is installed on the plant, it is necessary to follow a few rules during the storage period:

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

2. Ensure that plastic caps are fitted to protect the pneumatic/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.

3. If the storage is outdoor, or if long-term storage (more than 4 months) is necessary, the plastic protection plugs must be
replaced by metal plugs, because the plastic plugs are not weather-proof, whereas the metal ones guarantee a weather-proof
protection.

4. The actuator, with its mechanical and hydraulic overrides, must be placed on a wooden pallet in order to not damage the
coupling base and to prevent other surfaces from resting on the ground.

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

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

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

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

d. It is important to periodically operate the actuator and its accessories.

1.9 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. 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.

1.10 Unpacking

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

2. Report transport damage to the carrier immediately.

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

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

6

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

Mechanical Manual Overrides

2

Mechanical Manual Overrides on LFPS heavy duty and compact actuators provide an economical and durable method for manually
operating the actuators. LFPS Mechanical Overrides are designed in accordance with EN 12570 Standard. The manual force to operate
the actuator shall not exceed the values stated in EN 12570, when measured at the outermost point of the handwheel.

LFPS Mechanical Manual Overrides are available in the following versions:

• Enclosed Jackscrew (-JS)

• Not Enclosed Jackscrew (-JL)

• Bevel gear (-BG)

They are designed and standardized depending on the Actuators series, however special versions are available upon request.

a CAUTION: prior to operating an actuator by means of manual overrides, be sure to remove the pressure inside the cylinder and

that the cylinder has been vented to atmosphere through the venting ports. Ensure that all vent valves are in vent position. The
number of vent valves varies by actuator and control schematic types.

2.1 Enclosed Jackscrew Manual Override (-JS)

The Enclosed Jackscrew is a direct operating handwheel, which means that a rotating screw can be fitted either on the cylinder side
(single-acting actuators LPS series) or on the scotch-yoke housing (double-acting actuators LPS series). The rotation of the hand­wheel in clockwise (CW) or counterclockwise (CCW) directions will cause the consequent rotation of the scotch-yoke mechanism and
the stem of the valve which the actuator is fitted on.

The Enclosed Jackscrew has a totally enclosed and protected design, with no externally exposed threads or moving parts, which
makes this manual override suitable for severe and saline environmental conditions.

Travel Stop

Seal Nut

Seal Nut

Travel Stop

Figure 1 – Enclosed Jackscrew Manual Override for Double-Acting Actuators (left) and Single-Acting Actuators (right)

The Enclosed Jackscrew option is available for the LPS-15 and LPS-20 single-acting and double-acting versions.

7

flowserve.com

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

2.1.1 Installation - Travel-Stop Bolts Adjustment Enclosed Jackscrew Override Installed on
Single and Double Acting Actuators

All actuated valves require accurate travel-stop adjustments at both ends of the stroke to obtain optimum performance and valve
seat life. Adjust the travel-stop bolts of the actuator for the proper open and close valve positions, according to Flowserve valve
manufacturer’s recommendations.

The Enclosed Jackscrew manual override (-JS) has a travel-stop adjustment in one direction: valve open direction (in double-acting
and single acting fail-open) or valve close direction (in single-acting fail close). The travel stop adjustment in the opposite direction
must be performed in accordance with the IOM of the actuator.

The +/- 5 degree adjustment feature provides shaft rotation from 80 to 100 degrees overall.

The adjustment of the travel-stops is performed in accordance with the following steps:

2.1.1.1 Loosen the seal nut with a proper wrench (Figure 1).

2.1.1.2 While keeping the seal nut stationary, screw or un-screw the travel-stop (Figure 1) bolt using a proper Allen key.

2.1.1.3 Tighten the seal nut.

2.1.1.4 Pneumatically stroke the actuator several times to assure proper operation. The stem adaptor should not bind during
operation. If the actuator is equipped with limit switches, positioners or other accessories, adjust them at this time according
to their specific installation manuals.

2.1.2 Operation – Enclosed Jackscrew Override Installed on Single-Acting Actuator

Figure 2 – LPS Single-Acting with Enclosed Jackscrew Override

2.1.2.1 Manual Operation

a CAUTION: prior to operating the actuator by mean of manual overrides, be sure to remove the pressure inside the cylinder and

that the cylinder has been vented to atmosphere through the venting ports. Ensure that all vent valves are in vent position. The
number of these valves varies as per the actuator and control schematic types.

To manually operate the override:

8

2.1.2.1.1 Remove the supply pressure inside the actuator’s cylinder and vent the cylinder ports.

2.1.2.1.2 Operate the handwheel clockwise (CW) to close the valve (both on fail close and fail open actuators).

Mechanical and Hydraulic Overrides FCD LFENIM0004-00-AQ – 05/15

2.1.2.1.3 Operate the handwheel counterclockwise (CCW) to open the valve (both on fail close and fail open actuators).

NOTE: The spring constantly loads the screw and it returns the actuator to fail-safe position when the jackscrew is retracted
(rotating clockwise (CW) on a fail close actuator and rotating counterclockwise (CCW) on a fail open actuator).

2.1.2.2 Restoring Automatic Operation

To restore the automatic operation:

2.1.2.2.1 Operate the handwheel in order to completely retract the jackscrew (rotating clockwise (CW) on a fail close actuator and
rotating counterclockwise (CCW) on a fail open actuator) and lock the position with the safety lock

2.1.2.2.2 Restore the supply pressure inside the actuator’s cylinder.

2.1.2.2.3 Operate actuator normally with supply pressure.

2.1.2.2.4 Check that the actuator is able to reach the fully close position in case of fail close actuator or the fully open position in case
of fail open actuator. It is possible to check the fully-stroked position by viewing the position indicator or limit switches,
if fitted. If the actuator is not able to fully stroke in fail-safe direction, verify that the jackscrew has been totally retracted,
rotating it as described in step 2.1.2.2.1.

1

The safety lock is only available upon request. Please contact your local Flowserve Limitorque Representative for more information.

1

.

2.1.3 Operation – Enclosed Jackscrew Override Installed on Double-Acting Actuator

Figure 3 – LPS Double-Acting with Enclosed Jackscrew Override (Declutchable)

2.1.3.1 Manual Operation

a CAUTION: prior to operating the actuator by mean of manual overrides, be sure to remove the pressure inside the cylinder and

that the cylinder has been vented to atmosphere through the venting ports. Ensure that all vent valves are in vent position. The
number of these valves varies as per the actuator and control schematic types.

To manually operate the override:

2.1.3.1.1 Remove the supply pressure inside the actuator’s cylinder, and vent the cylinder ports.

2.1.3.1.2 Rotate the lever on the manual override from “DISENGAGED” to “ENGAGED” position (see Figure 4).

2.1.3.1.3 Operate the handwheel clockwise (CW) to close the valve.

2.1.3.1.4 Operate the handwheel counterclockwise (CCW) to open the valve.

9

flowserve.com