rotork LP/S Series Installation, Comissioning And Maintenance Manual

LP/S Range

Pneumatic Actuator

Single-Acting Configuration

Installation, Commissioning and

Maintenance Manual

Contents

Section Page Section Page

1.0 Introduction 3

2.0 Standards & Regulations 3

3.0 General Information 4

4.0 Health & Safety 4

4.1 Residual Risks 4

4.2 Thermal Risks 4

4.3 Noise 4

4.4 Health Risks 4

4.5 Mechanical Risks 4

4.6 Magnetic Risks 5

5.0 Labels & Nameplates 5

6.0 Operating Limits 6

6.1 Allowed Fluid Types 6

6.2 Expected Lifetime 6

6.3 Tightening Torque Chart 6

7.0 Handling & Lifting 7

7.1 Lifting Recommendations 7

7.2 Lifting Instructions 7

8.0 Storage 9

9.0 Long Term Storage 9

10.0 Installation on Valve 10

10.1 Preliminary Actions 10

10.2 Instructions 10

10.3 Assembly Configurations 11

11.0 Removal from Valve 11

12.0 Operation 12

12.1 D esc ription 12

12.2 Actuator Code and Design 13

12.3 Operating Description 14

12.4 Manual Override 14

12.5 Mechanical Manual Override
Single-Acting Actuator 15

12.6 Hydraulic Manual Override
Single-Acting Actuator 17

12.7 Linear Stroke Setting 18

12.8 Pneumatic Power Supply 21

12.9 Pneumatic Connections 21

12.10 Electrical Connections 22

12.11 Start Up 22

13.0 Dismantling & Disposal 23

14.0 Rotork Sales and Service 23

15.0 Troubleshooting 24

16.0 Periodic Maintenance 25

17.0 Part List 79

18.0 Grease & Hydraulic Oil Specification 87

18.1 Grease 87

18.2 Hydraulic Oil 87

This manual contains important safety information.
Please ensure it is throughly read and understood
before installing, operating or maintaining the
equipment.

Rotork reserves the right to modify, amend and improve
this manual without notice.

2

Installation, Commissioning and Maintenance Manual

Due to wide variation in the terminal numbering of
actuator products, actual wiring of this device should
follow the print supplied with the unit.

1.0 Introduction 2.0 Standards & Regulations

This manual covers maintenance aspects and instructions
specific to the LP range of actuators.

General information on Rotork fluid powered actuators is
included in the User Manual, delivered separately.

In this manual, warning indications are represented by icons,
per ISO 7010 Safety Signs:

Generic danger

Hand crush / pinch point

Electrocution

Explosive material

Customer Service

For technical assistance, please contact
Rotork Customer Service:

E-mail: [e-mail]

Rotork, Via Padre Jaques Hamel 138B,
Porcari, Lucca, IT. Tel: [phone]

Rotork plc, Brassmill Lane, Bath, UK. Tel [phone]

Actuators destined for European member states have been
designed, built and tested per the Quality Control System, in
compliance with the EN ISO 9001:2015 standard and with the
following regulations/directive.

•

2006/42/EC: Machinery Directive

•

2014/68/EU: Pressure Equipment Directive (PED)

•

2014/34/EU: Directive for safety equipment and systems
to be used in potentially explosive atmospheres (ATEX)

•

2014/30/UE: Electromagnetic Compatibility Directive

•

EN ISO 12100: Machinery Safety Directive

•

EN 60079-14: Explosive atmospheres – Part 14: Electrical
installations design, selection and erection

•

ISO 80079-36: Non-electrical equipment for explosive
atmospheres – Basic method and requirements

•

EN 1127–1: Explosive atmospheres – Explosion prevention
and protection

•

ISO 80079-37: Non-electrical equipment for explosive
atmospheres – Non-electrical type of protection
construction safety “c”, control of ignition sources “b”,
liquid immersion “k”

•

UNI EN ISO 7010: Safety Signals

Keeping the World Flowing

3

3.0 General Information 4.0 Health & Safety

This manual is produced to enable a competent user to
install, operate and maintain the Rotork LP Actuator
Single-Acting (LP/S).

The mechanical installation must be carried out as outlined
in this manual and in accordance with any relevant national
standard codes of practice.

Maintenance and operation must be carried out in
accordance with the National Legislation and Statutory
Provisions relating to the safe use of this equipment,
applicable to the site of installation.

Any inspection or repair in a Hazardous Area must not be
undertaken unless it conforms to National Legislation and
Statutory Provisions relating to the specific Hazardous Area.

Only Rotork approved replacement parts should be used.
Under no circumstances should any modification or alteration
be carried out on the equipment, as this could invalidate the
conditions under which its certification was granted.

Only trained and experienced operators can install,
maintain and repair Rotork Actuators. Work undertaken
must be carried out in accordance with instructions in
this manual. The user and those persons working on this
equipment must be familiar with their responsibilities under
any statutory provisions relating to the Health and Safety of
their workplace.

Operators must always wear appropriate Personal Protection
Devices (PPDs) in line with the existing plant regulations.

Appropriate Usage

Rotork LP range actuators have been specifically developed to
motorize linear valves, such as gate valves, or globe valves.

Before installing the equipment, verify it is suitable for
the intended application. If unsure consult Rotork.

4.1 Residual Risks

Residual risks resulting from equipment risk evaluation
performed by Rotork.

4.2 Thermal Risks

Risk Hot/Cold surface during normal

operation (RES_01).

Preventive measures

Operators should wear protective gloves.

4.3 Noise

Risk

Preventive measures Operators should wear ear protections.

Noise >85 dB during operation (RES_05).

Operators should not stand near the
equipment during operation.

4.4 Health Risks

Risk Pressurized fluid ejection during

normal operation (RES_02).

Preventive measures All fittings must be properly sealed.

All fixing clamps must be correctly
tightened and sealed.

Risk Risk of intoxication (according to the

type of medium utilized) (RES_06).

Preventive measures Operators must use P.P.Ds and any

other equipment (breathing apparatus)
based on the type of supply medium.

Improper use can damage the equipment or cause
dangerous situations for health and safety. Rotork
declines any responsibility for damage to people and/
or objects resulting from the use of the equipment
for applications different from those described in the
present manual.

4.5 Mechanical Risks

Risk Uncontrolled movement (remote

operation) (RES_03) (This risk is
applicable only for actuators provided
with control panel).

Preventive measures Assure that the actuator cannot be

operated remotely. Prior to starting,
remove pneumatic supply, vent all
pressure vessels, and remove
electrical power.

Risk Presence of moving parts (centre body,

valve adapter) (RES_04).

Preventive measures Do not perform start-up or test

the actuator if the cylinder tube is
removed.

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Installation, Commissioning and Maintenance Manual

4.0 Health & Safety

1370

LUCCA ITALY

L

CYLINDER CODE:

SERIAL NUMBER

:

bar

bar

bar

L

MIN./MAX DESIGN TEMP.(TS):

CĀ

PED CAT.

:

FLUID:

MONTH/YEAR:

5.0 Labels & Nameplates

Risk Loss of stability with possible parts

projection (RES_08).

Preventive measures Do not disassemble the actuator

in case of malfunctioning. Follow
instructions in the manual and contact
Rotork.

Preventive measures Foresee periodic maintenance

procedure to verify tightening.

Risk Presence of potential energy (RES_10)

during dismantling.

Preventive measures Do not disassemble the actuator

during dismantling. Follow instructions
in the manual and contact Rotork.

4.6 Magnetic Risks

Risk Risk of magnetic field/disturbance and

exothermic reactions.

Preventive measure The end user shall assure that actuator

and its components are installed
far from magnetic field, electro­magnetic field, radioactive source,
electroacoustic transducer which could
modify its behaviour.

(This mitigation is applicable only for

actuators provided with control panel).

Avoid maintenance operations with

acid/basic solutions.

The following label is applied externally to the actuator:

Fig 5.1 Actuator label

The TX surface temperature class is not provided since the
actuator has no internal heat source. Maximum actuator
temperature is near the environmental or exercise fluid
temperature, whichever is the greater. Normal operating
temperature range is -30 to +100 °C. Temperature range is
specified within the project specific technical documentation.
Special applications out of previous range are available
upon request.

ATEX plate does not indicate the maximum environmental
and/or exercise fluid temperature; this information is reported
within the project specific technical documentation.

For CE (PED) marked actuator the following label is also used:

Fig 5.2 Actuator PED label

Label removal is not allowed.

Keeping the World Flowing

5

6.0 Operating Limits

Temperature: -30 to +100 °C for standard applications

-20 to +100 °C for PED applications

-40 to +100 °C for low temperature

application

-60 to +100 °C for ultra-low

temperature application

Design pressure: up to 12 barg

Operating pressure: up to 12 barg

Do not use the equipment outside its operating limits.
Verify operating limits on the nameplate.

Prevent external surface temperature to reach the ignition
point in potentially explosive environments.

The actuator surface temperature is strictly dependent on the
temperature of the process fluid used and by the irradiation’s
conditions. The end-user must check the surface temperature
of the assembly, so that this cannot go over the minimum
gas ignition’s temperature, which classifies the area with the
explosion’s risk.

Dust and debris accumulated on the actuator will slow down
its cooling and contribute to the increase of its external
temperature.

6.3 Tightening Torque Chart

RECOMMENDED TIGHTENING TORQUE

(Class 8.8 bolts)

Bolt Size Nm Ft. Lbs

M6 8.5 6

M8 20 15

M10 40 30

M12 55 40

M14 110 81

M16 220 162

M20 430 317

M22 425 313

M24 585 431

M27 785 579

M30 1250 921

M33 1400 1030

M36 1750 1290

M48 5000 3688

M64 9200 6786

6.1 Allowed Fluid Types

The pneumatic actuator is designed to be operated with
Gas, Instrument air with particles filtering ≤ 40 µm (Class 7
according ISO 8573-1, table 1), pressure dew point ≤ -20°C
(Class 3 according ISO 8573-1, table 2), total concentration of
oil ≤ 5 mg/m3 (Class 4, according ISO 8573-1, table 3); if not
differently specified in specific project documentation.

Do not use the actuator in presence of naked flames.

6.2 Expected Lifetime

Expected lifetime greater than 25 years, in normal service
conditions and with planned maintenance.

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Installation, Commissioning and Maintenance Manual

7.0 Handling & Lifting

Only trained and experienced personnel should

handle/lift the actuator.

The actuator is supplied packed on pallets suitable for normal
handling.

•

Angle β must be between 0° and 45° as shown below.

Handle the actuator with care. Never stack pallets.

7.1 Lifting Recommendations

•

The lifting device and the sling must be suitably rated for
the actuator weight and dimensions

•

Do not use damaged sling(s)

•

The sling must not be shortened with knots or bolts or
any other makeshift device

•

For lifting purposes, use only suitable lifting tools

•

Do not drill holes, weld eye bolts or add any other type of
lifting device on the actuator external surface

•

Do not lift the actuator and valve combination with the
actuator lifting lugs

•

Every assembly must be estimated separately for a safe
and correct lifting

•

Avoid pulls or abrupt movements during lifting. Avoid
pushing the load

•

During lifting operations, do not handle the slings and/or
the actuator

Do not step underneath suspended load.

Direction

of Pull

7.2 Lifting Instructions

NOTE: Indication of weight, centre of gravity,
lifting points are reported within specific project
documentation.

For non-horizontal actuator orientation, please consult
project specific documentation before lifting.

•

Prior to lifting the actuator, remove electrical power and
vent all pressure vessels (if present)

•

In case of actuator equipped with 2 eye bolts, hook the
chains on them both, as shown in Fig 7.1

•

In case of actuator equipped with 4 eye bolts, hook the
chains on the 4 of them, as shown in Fig 7.2

The actuator must remain vertical; balance the load.

Keeping the World Flowing

7

7.0 Handling & Lifting

Fig 7.1 Lifting LP/S type 0 Fig 7.2 Lifting LP/S type 1 and type 2

8

Installation, Commissioning and Maintenance Manual

8.0 Storage

9.0 Long Term Storage

Rotork actuators are fully tested before leaving the factory.

To keep actuator in good condition until installation, at least
the following measures are recommended:

•

Check presence and assembling of dust plugs

•

Keep the actuator on shipping pallet until installation

Never put the actuator directly on the ground.

•

Actuator must be positioned with the centre body
cover upwards

•

Protect the valve coupling area (adapter flange
and coupling joint, etc.) with rust preventive oil
e.g. Mobilarma LT or equivalent

•

Protect against weather action, covering the actuators
with appropriate polyethylene sheets

•

Check the actuator condition every six months and verify
the above protection measures remain in place

Remove package only at the installation time.

If long term storage is necessary, further operations must
be carried out to maintain the actuator in a good working
condition:

•

Replace the plastic plugs with metal plugs

•

Stroke the actuator every 12 months

•

Cycle the actuator (using filtered, dehydrated air) to the
working pressure indicated on the name plate

•

Cycle the actuator with all the existing controls
(i.e. two complete strokes – one open, one closed)
at least five times

•

Cycle the actuator fitted with the mechanical manual
override or hydraulic manual override by means of the
override for four complete strokes

•

Disconnect the pneumatic and electric (if present)
supply from the actuator, and carefully close all the
threaded connections of the actuator

•

Remove electrical components covers (if present) to
ensure control terminals are clean and free from oxidation
and humidity. Reassemble the covers

•

In case of storage for over 12 months prior to installation,
it is recommended to operate the actuator to verify
correct operation

Keeping the World Flowing

9

10.0 Installation on Valve

Before proceeding, read and understand the Health and
Safety information.

Note: The valve should be properly secured prior to
performing the following operations according to
instructions provided by the Valve Manufacturer.

Prior to performing any operations check the
operating drawings and TAG numbers.

Consult Rotork for any additional information.

10 .1 Preliminary Actions

Verify the ATEX classification of the actuator is
compatible with the plant zoning. Refer to actuator
nameplate.

•

The centreline of the cylinder is usually perpendicular to

the centreline of the associated pipe work

•

Ensure all fasteners are adequately tightened, to avoid

loosening during operation, considering the vibrations

induced by the dynamics of the pipeline

•

Piping used to provide power to the actuator must be

free from contaminants and debris. Ensure tubing runs

are adequately fastened and supported to minimize

repetitive stress induced the dynamics of the pipeline.

Ensure there are no leaks from any gas connections.

Tighten as required

10.2 Instructions

The actuator assembly on valve can be performed using
an adapter and a coupling joint between the actuator and
the valve.

The assembly position of the actuator must be in
accordance with the actuator design, plant requirements
and the valve model.

Installation must be performed by qualified personnel.

Hands must be kept away from the coupling area.

To assemble the actuator onto the valve, proceed as follows:

•

Actuator is supplied in the fail position (for single-acting).

Set the valve in the right position per the actuator fail

position. Check the position of the actuator by means

of the actuator stem position or on the limit switch box

(if present)

•

The actuator is supplied with the spool piece installed –

do not remove it

•

Clean the coupling flange of the valve and remove

anything that might prevent adherence to the actuator

flange. Grease shall be completely removed

•

Place the valve in a vertical position

Standard coupling is constituted by the following standard
parts (see Fig 10.1):

•

Actuator side joint

•

Coupling clamp

•

Ring

•

Screws

Actuator side

Clamp

Screw

Valve side

Fig 10.1 Standard coupling parts

•

Fasten the actuator side joint on the actuator stem

•

Fasten the valve side joint on the valve stem

•

Lift the actuator according to instructions in section 7.0

•

Place the ring on the actuator stem holding it with the
hand and lower the actuator on the valve – the two joints
are now in touch

•

Place the two clamps on the joints

•

Lower the ring in position and fasten all the screws

•

Tighten bolts or nuts between actuator spool piece and
valve top flange to the correct torque, in accordance with
the size and material characteristics of the bolts installed
by the customer

Support the actuator until fully installed and fixing

bolts are correctly tightened.

•

Check for possible damage to the paint-work and repair if
necessary, according to painting specification

Clamp

Ring

Screw

10

Installation, Commissioning and Maintenance Manual

10.3 Assembly Configurations

10.0 Installation on Valve 11.0 Removal from Valve

The end user is in charge of removing the actuator
from the valve.

Removal shall be performed only by qualified staff,

wearing/using appropriate personal protection devices.

Do not remove the actuator if the valve is blocked
in the intermediate position. Contact Rotork Customer
Service.

To disassemble the actuator from the valve, proceed as
follows:

•

Cut off electrical power supply

•

Cut off pneumatic supply

•

Release any pressure from the control group

•

Remove the supply pipes from the actuator

•

Remove control and signal lines from electric components

(if any)

•

Sling the actuator in line with the instructions given in

section 7.0

•

Unscrew bolts or nuts from the stud bolts fixing the

actuator to the valve

•

Lift and remove the actuator from the valve

Fig 10.2 Actuator/valve assembling example

Keeping the World Flowing

11

12.0 Operation

The following instructions must be followed and integrated
into end user safety program when installing and using
Rotork products. Read and save all instructions prior to
installing, operating and servicing this product.

Follow all warnings, cautions and instructions marked on and
supplied with the product.

Install equipment as specified in Rotork installation
instructions and as per applicable local and national
codes of practice. Connect all products to the proper
pipeline gas sources.

When replacement parts are required, ensure that the
qualified service technician uses only replacement parts
specified by Rotork.

Substitutions will invalidate any hazardous area certification
and may result in fire, electrical shock, other hazards or
improper operation.

12 .1 Description

The LP/S series actuators are pneumatic single-acting –
spring-return actuators specifically designed to provide
efficiency and reliability in heavy duty services.

These actuators can be assembled in a ‘spring down’ (LP/SD)
or in a ‘spring up’ (LP/SU).

Model LP/SD is air to retract actuator stem, while spring
extend it.

Model LP/SU is air to extend actuator stem, while spring
retract it.

Main components of a LP/S actuator are:

• A pneumatic cylinder

The cylinder tube is electroless nickel plated internally, to
assure perfect dynamic seal, corrosion resistance and low
friction. Carbon steel piston with dynamic O-ring seal and
guide sliding ring allow for friction reduction which avoid
sticking even after long standstill periods.

Chromium plated and polished piston rod ensures a
corrosion resistance and low friction. The piston rod is
supported by bushing made of bronze and Teflon to
reduce friction and to guarantee a long operating life.

The dynamic cylinder seals are specifically designed to
enable the use without lubrication.

• A spring cartridge
a frame assembled spring package that prohibits the
spring from extending beyond a pre-set length. The
container allows safe installation and removal of the
whole cartridge assembly.

•

An

adapter spool open type

bottom flange machined per the valve flange and it is
removable from the actuator. The open adapter allows for
easy visual position indication and is suitable for installing
a limit switch box, junction box etc.

• A connecting joint
mating the actuator piston rod to the valve stem.

An optional coupling with hammer blow effect that
facilitates release of wedge gate valves is available upon
request.

Upon request, LP series actuators can be equipped with
additional accessories (limit switches box, positioner, position
transmitter, control panel, etc.)

Use only control devices supplied by Rotork.

, made of carbon steel.

consisting of an enclosure containing

made in carbon steel, with

made of nickel plated carbon steel for

12

Installation of any accessory on the bare actuator

must preserve the actuator Ingress Protection level.

Installation, Commissioning and Maintenance Manual

12.0 Operation

L P / S D - 9 3 5 A / M -

- H P

ACTUATOR TYPE

L = LI NEAR T YPE

SUPPLY TYPE

P = Pneu matlic

ACTION

SD = SINGLE A CTING SPRI NG DOWN

SU = SIN GLE ACTING SPRI NG UP

CYLINDER SIZE in mm

TEMPERATURE

LP (Pneum atic)

A = St andard

B = High

C = Low

E = E xtreme low

SPRING CODE

E, B, D, E , W15, W13, W3, H, L, F , M, G, Y1 8, W19, W16, W25

SIZE
M1, M2, A1 , A2, A3, B1, B2, B 3, C1, C2, C3, D1, D2, D 3

MANUAL OVERRIDE TYPE

MH, MHD, HP

12.2 Actuator Code and Design

Below the actuator reading key:

The LP/S actuator is available accordingly to 3 designs:

•

Type 0

•

Type 1

•

Type 2

Below the applicability chart per each type, based on the
cylinder size and spring code.

Actuator

cylinder size Spring Type

140 all sizes 0

D 1

180

200

235

250 all sizes 1
280 all sizes 1
300 all sizes 1
335 all sizes 1
385 all sizes 1
435 all sizes 1
485 all sizes 1
535 all sizes 1
585 all sizes 1
635 all sizes 1
685 all sizes 1
735 all sizes 2
785 all sizes 2
835 all sizes 2
935 all sizes 2
940 all sizes 2

Description of the 3 designs is as follows.

B 0

AB 0

D 1
AB 0
AB 0
DE 1

E 1

D 1

W15 1
W13 1

W3 1

Actuator LP/S Type 0

Main components of LP/S type 0 actuator are shown
in Fig 12.1 and Fig 12.2.

1

2

4

3

Fig 12.1 LP/S Type 0 without stop bolt main components

5

2

4

3

Fig 12.2 LP/S type 0 with stop bolt main components

Table 1: LP/S type 0 Parts List

IT DESCRIPTION QTY

1 Plug 1

2 Cylinder tube 1

3 Spool piece 1

4 Valve connection 1

5 Stop bolt 1

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13

12.0 Operation

Actuator LP/S Type 1 and 2

Main components of LP/S type 1 and type 2 actuator are
shown in Fig 12.3, Fig 12.4, Fig 12.5 and Fig 12.6.

Type 1 and type 2 differs in the spring package type installed,
but since the latter must not disassembled for safety reasons,
from a maintenance point of view can be regarded as identical.

1

2

4

5

Fig 12.3 LP/S type 1/type 2 without stop bolt main components

6

2

12.3 Operating Description

Please refer to the Operating Diagram supplied for the
specific actuator.

12.4 Manual Override

The LP series can be fitted with an emergency manual
override suitable to operate the actuator in the event of fluid
supply failure.

This device can be of mechanical screw type operated by
means of a handwheel, or of hydraulic type, with a hydraulic
cylinder operated using a hydraulic hand pump.

A maximum operating time of the manual override
of 24 hours, for maintenance or testing,
is recommended.

Note: The use of manual override is not recommended
in SIL applications. If it is necessary, strictly follow
instructions reported in the following paragraphs.

Before operating the mechanical manual override, ensure
that the cylinder is not pressurized and that the actuator is in
the fail position, then proceed as indicated in the following
paragraphs.

Important:

“M” jackscrew and grease it afterwards.

Use a Molykote HSC PLUS grease.

been disengaged before returning to remote operation.

The manual override can be of mechanical type or
hydraulic type.

It is recommended to regularly clean the

After each use, verify that the manual override has

3

5

Fig 12.4 LP/S type 1/ type 2 with stop bolt main components

Table 2: LP/S type 1/type 2 Part s list

IT DESCRIPTION QTY

1 Plug 1

2 Spring cartridge 1

3 Cylinder tube 1

4 Spool piece 1

5 Valve connection 1

6 Stop bolt 1

14

Installation, Commissioning and Maintenance Manual

4

12.0 Operation

12.5 Mechanical Manual Override Single-Acting Actuator

The mechanical manual override can be of two types:

•

Type MH: With a jackscrew with protection pipe

•

Type MHD: With a jackscrew with protection pipe and a
declutch able handwheel

Type MH mechanical manual override

Fig 12.5 Type MH mechanical override up to actuator

Type MH mechanical manual override

cylinder size 200

Instructions to engage or disengage the override are reported
on the plate installed on manual override:

Fig 12.7 Type MH manual override plate

Before re-starting the actuator with air supply,
rotate the jackscrew again to set the actuator in its
original position.

Fig 12.6 Type MH mechanical override up to actuator

Fail to close, single-acting actuator:

•

Rotate the handwheel counter-clockwise to open
the valve

Fail to open, single-acting actuator:

•

Rotate the handwheel clockwise to close the valve

cylinder size 385

Keeping the World Flowing

15

12.0 Operation

Type MHD mechanical manual override

Fig 12.8 Type MHD mechanical override up to actuator

cylinder size 200

Instructions to engage or disengage the override are reported
on the plate installed on manual override:

Fig 12.10 Instructions plate for MHD manual override

Fail to close, single-acting actuator:

•

Rotate the handwheel counter-clockwise to open
the valve

Fail to open, single-acting actuator:

•

Rotate the handwheel clockwise to close the valve

Before re-starting the actuator with air supply,

rotate the jackscrew again to set the actuator in its
original position.

Fig 12.9 Type MHD mechanical override up to

•

ENGAGE PROCEDURE: Pull disengaging knob and
handwheel at the same time; rotate the handwheel until
the manual override gets engaged

•

DISENGAGE PROCEDURE: Pull disengaging knob and
push the handwheel, at the same time

When the manual override is disengaged, the handwheel
operation is neutral and the actuator can be operated
pneumatically.

cylinder size 385

16

Installation, Commissioning and Maintenance Manual

12.0 Operation

12.6 Hydraulic Manual Override Single-Acting Actuator

Type HPA hydraulic manual override

The unit consists of two main components:

•

the hydraulic cylinder

•

the pump/tank assembly

The hand pump (1) supplies high-pressure fluid to the
hydraulic cylinder (2) that will stroke the actuator and
compress the spring.

2

3

4

1

5

Filling procedure

If the actuator is shipped without oil in the HPA, please refer
to filling procedure described in PM-LP-005.

Operation with Hydraulic Pump

•

The manual valve (4) must be in the open position

•

Close the on/off selector valve (5) by turning in fully
clockwise

•

Operate the pump (1) via the handle (3) will stroke the
actuator and compress the spring

•

When the actuator has reached the desired position of
travel, it can be locked in position by closing the manual
valve (4)

•

To allow the spring to decompress, the manual valve
(4) must be moved to the open position and the on/off
selector valve (5) backed out by turning anti-clockwise

After each use, verify that the manual override has

been disengaged.

Fig 12.11 Type HPA manual override

Installation

The oil tank must be installed in a vertical position with
respect to the floor. The fill port/breather (4) must be turned
upward to avoid any oil discharge from the fill port/breather
of the tank.

NOTE: Before starting-up the actuator with a hydraulic
override, check if the plug (4) has been replaced with a
breather to prevent oil discharge from the tank during
shipment.

If not, replace the plug with the breather.

Proper oil level is approximately 25 mm (1") below the fill/
breather port.

Oil level should be checked with the tank in a vertical position
and with the actuator in fail position (spring decompressed).

Keeping the World Flowing

17

12.0 Operation

12.7 Linear Stroke Setting

Certain valves incorporate their own stops. For such
valves, it is recommended that the actuator stop bolt
positions coincide with the valve stop position.

Contact the valve manufacturer to set the valve
mechanical stops.

An incorrect setting of linear stroke could cause
damages to actuator, valve and/or to personnel.

Single-acting actuator type 0,
cylinder stop bolt setting

Perform the following operations as first setting.

Adjust the stop bolt located in the end flange of the cylinder
as follows:

1

1

2

3

H. With the help of a suitable size wrench, rotate the stop

bolt (3) clockwise to decrease the angular stoke

I. Remove the pressure

J. Verify the newly obtained angular position with one

stroke

K. Repeat operations H to J, until the desired angle is

obtained

L. Re-position the O-ring (2) between flange and the

stop nut (1)

1

2

A. Verify the absence of pressure

B. Loosen stop nut (1) and remove the O-ring (2)

C. Slowly pressurize the cylinder to detach stop bolt

from piston

1

2

3

D. With the help of a suitable size wrench, rotate the stop

bolt (3) counter clockwise to increase the angular stoke

E. Remove the pressure

F. Verify the newly obtained angular position with one stroke

G. Repeat operations A to F, until the desired angle is

obtained

M. Hold the stop bolt (3) with a wrench and carefully tighten

the stop nut (1)

3

1

18

Installation, Commissioning and Maintenance Manual

12.0 Operation

Single-acting actuator, type 1 and type 2,

cylinder stop bolt setting

Perform the following operations as first setting.

Adjust the stop bolt located in the end flange of the cylinder

as follows:

5

2

3

1

A. Verify the absence of pressure

B. Remove cap nut (5) and O-ring (2)

C. Loosen stop nut (1)

D. Slowly pressurize the cylinder to detach stop bolt

from piston

I. With the help of a suitable size wrench, rotate the stop

bolt (3) clockwise to decrease the angular stoke

J. Remove the pressure

K. Verify the newly obtained angular position with one stroke

L. Repeat operations I to L, until the desired angle is obtained

3

1

M. Hold the stop bolt (3) with a wrench and carefully tighten

the stop nut (1)

5

2

3

E. With the help of a suitable size wrench, rotate the stop

bolt (3) counter clockwise to increase the angular stoke

F. Remove the pressure

G. Verify the newly obtained angular position with one stroke

H. Repeat operations E to G, until the desired angle

is obtained

3

N. Re-position the O-ring (2) and verify it is correctly

positioned. Tighten cap nut (5)

Keeping the World Flowing

19

12.0 Operation

Single acting actuator with HPA type manual override,
cylinder stop bolt setting

Perform the following operations as first setting.

Adjust the stop bolt located in the end flange of the hydraulic
cylinder, as follows:

A. Verify the absence of pressure

B. Loosen cap nut (5) with relative seal washers (7) and (8)

and loosen stop nut (6)

5

7

3

8

6

H. To decrease linear stroke, rotate stop bolt (3) clockwise

I. Remove pressure

J. Verify the newly obtained angular position with one stroke

K. Repeat operations A to C and H to K, until the desired

angle is obtained

8

L. Position seal washer (8)

M. Hold stop bolt (3) with a wrench and tighten the stop nut (6)

3

6

C. Slowly pressurize the cylinder to detach stop bolt (3)

from piston

D. To increase linear stroke, rotate stop bolt (3) anti-clockwise

E. Remove pressure

F. Verify the newly obtained angular position with one stroke

G. Repeat operations A to F, until the desired angle

is obtained

3

N. Insert seal washer (7) and verify it is correctly positioned.

Hold stop nut (6) with a wrench and tighten cap nut (5)

5

7

6

20

Installation, Commissioning and Maintenance Manual

12.0 Operation

12.8 Pneumatic Power Supply

Verify allowed supply pressure range on actuator label.

Verify medium composition. Contact Rotork to check

the compatibility with the supply medium.

12.9 Pneumatic Connections

Preliminary Operations

A. Verify sizes of pipes and fittings according to applicable

plant specifications

B. Clean the inside of the connection pipes by washing them

with a suitable detergent and by blowing air into them

C. The connecting pipes must be properly shaped and fixed

to prevent stress or loosening of threaded connections

NOTE: For tapered-thread fluid connections, apply a

thin layer of thread sealing product (Loctite 577 or

equivalent) to ensure a good seal.

Exhaust port

Inlet port

Fig 12.12 Inlet / Exhaust port for spring down actuator

Connect the pneumatic power source in accordance
to the applicable operating diagram, please refer to
specific job for details.

Depending upon the control circuit design,
pneumatically powered actuators may exhaust the
power supply gas into the atmosphere during normal
operation. This may present an unacceptable hazard.

Do not feed a single-acting actuator from the
spring container side after having removed the exhaust
silencer, especially if the line valve is blocked.

Inlet port

Exhaust port

Fig 12.13 Inlet / Exhaust port for spring up actuator

Keeping the World Flowing

21

12.0 Operation

12 .10 Electrical Connections

Check electrical components supply voltage,

before start-up.

Access to live electrical conductors is forbidden in

hazardous areas unless done under a special permit.
Otherwise, all power should be isolated and the unit
moved to a non-hazardous area for repair.

Prevent electrostatic charges in potentially

explosive areas.

Electrical connection can be performed as follows:

•

Remove power supply

•

Remove the plastic protection plugs from the cable
entries

•

Use only appropriately certified reduction fittings, cable
glands, fittings and explosion-proof cables

•

The cable glands must be tightened in the threaded
inlets, to guarantee the waterproof and explosion proof
protection

•

Pay attention to the correct installation of the O-rings of
the cable glands to prevent water and debris infiltration
inside electric components

•

The size of the electric supply cable must be suitable for
the electrical power required

•

Insert the connection cables through cable glands
and perform assembly according to the cable gland
manufacturer’s instructions

•

Connect the cable wires to the terminal blocks in
accordance with the applicable wiring diagram

•

Electric connections must be made by using rigid conduits
and trailing cables to prevent mechanical stresses in the
cable entries

•

On the unused entries of the junction box, replace
the plastic plugs with approved metal plugs, to
guarantee sealing and comply with explosion safety
protection codes

•

Assemble the covers of the electric components, paying
attention to seals

•

Once connections have been completed, check electrical
components functionality

12 .11 Start Up

During the start-up of the actuator, it is necessary to check if:

•

Medium supply pressure is as prescribed

•

The feed voltage values of electrical components
(solenoid valves coils, limit switches, pressure switches
etc., if applicable) are as prescribed

•

Actuator controls such as remote control, local control,
emergency control etc. (if applicable) work properly

•

Input remote signals are correct

•

The setting of control unit components is according to the
plant requirements

•

Pneumatic connections show no leakage. If necessary,
tighten fittings

•

The painted parts have not been damaged during
transport, assembling or storage operations. Otherwise
remove presence of rust and repair the damaged parts
following the applicable painting specifications

•

Actuator and all its parties work as expected

•

Operating time is in accordance with requirements

The end user must guarantee equal voltage
potential between the valve and the actuator and
provide appropriate grounding. End user shall
indicate and maintain the grounding connections
on the actuator.

Actuator and electrical components must be
protected from electrical sparks, lightning, magnetic or
electro-magnetic fields, at user’s care.

22

Installation, Commissioning and Maintenance Manual

13.0 Dismantling & Disposal 14.0 Rotork Sales and Service

Prior to dismounting the actuator, ensure no parts are still

under pressure.

For Single-Acting Actuator

The spring cartridge module contains potential

energy due to compressed elastic elements.

After removing the spring cartridge from the centre body,

the spring cartridge must be returned to the manufacturer’s

plant, upon agreement with Rotork.

Grease and oil must be disposed of safely in
accordance with the local environmental laws and
regulations.

•

Dismount the actuator, separate and divide the various

components according to the type of material

•

Dispose of the pieces of steel, cast iron and aluminium

alloys as metal scraps

•

Dispose of the rubber, PVC, resins etc. separately, in

accordance with the existing national and regional

regulations

•

Electric components are to be separately disposed of on

specialized disposal sites

If your Rotork actuator has been correctly installed and
sealed, it will give years of trouble-free service. Should you
require technical assistance or spares, Rotork guarantees
the best service in the world. Contact your local Rotork
representative or the factory direct at the address on the
nameplate, quoting the actuator type and serial number.

Some actuators have a special spare parts list. Refer to the
project specific documentation for further details.

Actuators manufactured after 1993 do not contain asbestos
or its by-products.

Keeping the World Flowing

23

15.0 Troubleshooting

ID FAILURE POSSIBLE CAUSES CORRECTIVE MEASURES

1 Incorrect valve position •

2 Incorrect indication of valve position •

3 Incorrect movement

4 Valve stroke not fully completed

5 Leakages

6 Actuator moves too fast

7 Actuator moves too slow

8 Loss of power

Fault of pipeline valve

Incorrect signal from limit switches

•

Irregular supply of operating medium

•

Worn parts

•

Fault in control panel equipment
(if present)

•

Fault of pipeline valve

•

Insufficient gas flow

•

Incorrect assembly between actuator
and valve

•

Valve blocked

•

Stop bolts wrong setting

•

Stop bolts wrong setting

•

Worn seals

•

No pressure on pipeline

•

Supply pressure greater than allowed
range values

•

Fault on pipeline valve (valve hardened)

•

Supply pressure lower than allowed
range values

•

Possible internal undue friction

•

Inadequate supply pressure

•

Leakage from cylinder

•

Consult the valve manufacture’s documentation

•

Check limit switches position (see job specific
documentation)

•

Verify the supply pressure and adjust as
necessar y

•

Contact Rotork

•

Contact Rotork

•

Consult the valve manufacture’s documentation

•

Increase gas supply flow

•

Perform assembly according to section 10.0

•

Consult the valve manufacture’s documentation

•

Adjust stop bolt setting following instructions in
section 12.7

•

Adjust stop bolt setting following instructions in
section 12.7

•

Replace seals according to instructions reported
in PM-LP-006, PM-LP-007

•

Restore pipeline pressure

•

Verify the supply pressure and adjust as
necessar y

•

Consult the valve manufacture’s documentation

•

Verify the supply pressure and adjust as
necessar y

•

Contact Rotork

•

Ensure that the supply pressure is above the
minimum operating pressure of the actuator
and that the output torque produced at supply
pressure exceeds the required valve torque

•

Replace seals according to instructions reported
in

PM-LP-006, PM-LP-007

For other problems, please contact Rotork.

24

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

Rotork recommends performing the following checks to help comply with the rules and regulations
of the country of final installation:

Remove pressure before proceeding with maintenance operations, discharge any accumulators
or tanks (if present), except where otherwise indicated.

Periodic Maintenance Schedule

MAINTENANCE ACTIVITY PERIODICITY REFERENCE

Months Years

Visual check of external components and control groups 6* *

Verify welding. In case of anomalies contact RFS 6* *

Breather cleaning 6* *

Check pneumatic connections for leaks. Tighten pipe fittings as required - 1*

Cleaning - 1* PM-LP-001

Visual check of painting. Verify absence of damages. Repair if necessary
according to painting specification

Functional test - 1* PM-LP-002

Functional test by manual override - 1* PM-LP-003

Check electrical components (if present) and grounding connections - 1* PM-LP-004

Check threaded connections (bolts, studs and nuts) with valve. If necessary
tighten to the recommended torque, in accordance with the size and the
characteristics of the fastener material installed by the customer

Single-acting actuator hand pump oil replacement (if present) - 5* PM-LP-005

Pneumatic cylinder seals replacement type 0 - 5* PM-LP-006a

Pneumatic cylinder seals replacement type 1 and type 2 - 5* PM-LP-006b

Hydraulic cylinder for manual override seals replacement - 5* PM-LP-007

Manual handwheel MH and MHD seals replacement –
LP/SD and LP/SU actuator, cylinder up to size 235

Manual handwheel MH and MHD seals replacement –
LP/SD and LP/SU actuator, from size 235 to 385

(*) The time between maintenance tasks will vary depending on the medium and service conditions. Refer to End User Plant Preventive Maintenance
Program for specific task frequenc y.

- 1*

1*

- 5* PM-LP-008a

- 5* PM-LP-008b

For Functional Safety applications refer to Safety Manual.

Specific maintenance could be necessary for specific application.
Refer to job documentation for eventual additional maintenance tasks.

Keeping the World Flowing

25

16.0 Periodic Maintenance

PM-LP-001 Page:1/1

Component: Single-acting actuator Task: Cleaning

Equipment, Tools, Materials:

Air Compressor
Project documentation (Design and Operating pressure values)

Preliminary Operations:

Description:

Remove electric and pneumatic supply before proceeding.

1. Remove dust from actuator external surface with a dust rag and by blowing air

Do not polish/rub non-metal surfaces with a dry cloth. The tools and cleaning procedures must not produce sparks or create
adverse conditions in the environment during maintenance operations, to prevent potential explosion hazards.
Prevent electrostatic charges in potentially explosive areas.

Warnings:

26

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-002 Page:1/1

Component: Single-acting actuator Task: Functional test

Equipment, Tools, Materials:

Chronometer

Project documentation (required stroke times)

Preliminary Operations:

Description:

NOTE: Actuator must be connected to the pneumatic supply to perform the following test.

1. Operate the actuator

2. Perform the stroke several times by local and remote (if applicable) control

Actuator could exhaust medium supply in the atmosphere during normal operation.

Wear PPD including breathing device in function of type of medium supply used.

3. Verify actuator is correctly working

4. Note the stroke time(s)

5. Verify stroke time(s) are as required

In case of stroke times out of required range refer to Troubleshooting ID 4, 5 (see page 24) to restore.

Warnings:

Keeping the World Flowing

27

16.0 Periodic Maintenance

PM-LP-003 Page: 1/1

Component: Mechanical manual override Task: Manual override functional test

Equipment, Tools, Materials:

Project documentation

Preliminary Operations:

Description:

Opening operation

1. Verify the absence of pressure

2. Verify the actuator is in its fail position, spring relaxed (for single-acting actuator)

3. Move the mechanical manual override according to instructions reported in MANUAL OVERRIDE page 14 to stroke the actuator

4. Verify the actuator reaches the desired position

Before re-starting the actuator with air supply, disengage the manual override to set the actuator in its original position.
After each use, verify that the manual override has been disengaged before returning to remote operation.

Warnings:

28

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-004 Page: 1/1

Component: Electrical components (if present) Task: Check electrical components (if present) and grounding

connections

Equipment, Tools, Materials:

Project documentation

Preliminary Operations:

Description:

Switch off electric power supply before working on electrical devices.
Read and follow the safety precautions reported in the Manufacturer’s Maintenance Manual.
Risk of temporary modification of the component protection.

Use only antistatic clothes.

1. Remove cover from electric components

2. Check electric device components

3. Verify tightness of terminal blocks

4. Verify absence of humidity and oxidation

5. Check cable gland seals

6. Verify grounding connection and restore if necessary

Warnings:

Keeping the World Flowing

29

16.0 Periodic Maintenance

PM-LP-005 Page: 1/1

Component: Hydraulic manual override for single-acting actuator Task: Hydraulic oil replacement

Equipment, Tools, Materials:

Project documentation
Wrench

Preliminary Operations:

Description:

Tasks must be executed with the tank in vertical position and with the actuator in fail position.
Verify the absence of pneumatic pressure.
Correct oil level is approximately 25 mm (1") below the fill/breather port.

Drain procedure

1. Make sure the actuator is in fail safe position (spring released)

2. Remove breather/plug (1.5)

3. Place containers under drain port (D1) to collect the fluid

4. Remove plugs (D1)

5. Discharge oil

6. Tighten plug (D1) back in its seat with a wrench

Used hydraulic fluid must be disposed of safely.

Warnings:

1.5

1

1.1

1.2

D1

Filling procedure

7. Fill with oil from the fill /breather port (1.5) up to 25 mm (1")
below the port

8. Close stop valve (1.2) and verify that stop valve (3) is open

9. Install the pump lever and operate pump (1.1) to fully compress
the spring

10. Ensure the oil level in the tank does not drop below the intake
tube

11. Slowly open stop valve (1.2) to allow the actuator the return to
the fail position

12. Repeat the pump operation procedure from 2 to 3 times

13. Pressurize and keep the cylinder pressurized from 3 to 5
minutes, to settle the oil level

14. Slowly open stop valve (1.2) to allow the actuator the return to
the fail position

15. Check the oil level. If necessary, fill in from the fill /breather port
(1.5) up to 25 mm (1") below the port

Important: Do not exceed this fluid level.

17. Reinstall the tank breather (1.5) and return the lever to the
storage holder

30

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006a Page: 1/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting clump
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

Description:

Note: the following instructions apply to single-acting actuator unless otherwise specified.

Cut-off power supply and electric power supply (if present) before performing any operation.

Adequate lifting devices and suitable for the weight must be applied by skilled personnel.

Preliminary actions

1. Remove actuator from valve and remove all couplings as well (see Removal from Valve, page 11)

2. Position the actuator on a workbench (if possible) or in a stable position and in a clean and closed area

3. Remove any control equipment (if present). Refer to the project specific documentation

4. Remove pneumatic pipes

APPLICABLE TO TYPE 0 WITH STOP BOLT ONLY (5)

5. Measure length (W)

Warnings:

W

6. Hold stop bolt (3) with a wrench and loosen and remove
stop nut (1)

3

Keeping the World Flowing

31

16.0 Periodic Maintenance

PM-LP-006a Page: 2/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

7. Remove O-ring (2)

8. Fully unscrew stop bolt (1)

If the stop bolt is hard to unscrew, pressurise the cylinder and unscrew
stop bolt by 3-4 turns.

Depressurize the cylinder; check if the stop bolt turns freely. If necessary,
repeat the operation.

Do not unscrew the stop bolt completely while the cylinder

is pressurized.

INSTRUCTION VALID FOR SPRING DOWN ONLY

9. Unscrew blind nuts (4) and nuts (5)

10. Remove end flange (6) with O-ring (7)

11. Remove cylinder tube (8) using suitable lifting tools

If, during the nuts (4) unfastening the end flange (6) suffers a
continuous load upwards along with nuts (4), stop and fasten
back the nuts (4). Contact Rotork Service Department.

At the beginning of the nuts (4) unfastening the flange (6) will be
pushed upwards by the pre-compressed spring load. If the upwards load
continues till the nuts (4) are almost fully unfastened, stop and fasten
them back. Contact Rotork Service Department.

Warnings:

1

2

3

4

5

6

7

32

8

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006a Page: 3/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals

Wrench

Lifting tools

Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

12. Remove spacer (9)

INSTRUCTION VALID FOR SPRING DOWN ONLY

13. Slide spring cartridge (10) piston (11) and piston rod (12)
away from head flange (13)

14. Remove O-ring (14)

Warnings:

9

10

11

12

14

13

Keeping the World Flowing

33

16.0 Periodic Maintenance

PM-LP-006a Page: 4/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

15. Unfasten screws (15) and remove spring cartridge away
from piston (11)

INSTRUCTION VALID FOR SPRING UP ONLY

16. Unscrew blind nuts (4) and nuts (5)

17. Remove end flange (6) with O-ring (7)

18. Remove cylinder tube (8) using suitable lifting tools

Warnings:

11

10

15

4

5

6

7

INSTRUCTION VALID FOR SPRING UP ONLY

19. Slide piston (11) and piston rod (12)

8

4

5

34

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006a Page: 5/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

20. Hold piston (11) and unscrew piston rod (12)

21. Remove sliding ring (17) and O-ring (18) from the piston

22. Remove O-ring (16)

When holding the piston, make sure the piston is not

scratched or deformed.

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

23. Unfasten screws (18) and remove head flange (13) from the
valve adaption (19)

Warnings:

12

19

17

18

11

16

13

18

Keeping the World Flowing

35

16.0 Periodic Maintenance

PM-LP-006a Page: 6/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

24. Unfasten screws (20) and remove flange (21)

25. Remove O-ring (22) and seals (23) and (24)

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

26. Carefully clean the seals grooves

27. All the removed parts must be thoroughly cleaned, inspected and de-burred as necessary

28. Replace all seals and lubricate them with a grease film

29. Lubricate all sliding parts. Use only recommended grease

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

30. Replace O-ring (22) and seals (23) and (24)

31. Replace flange (21) and fasten screws (20)

Warnings:

20

20

23

23

24

22

21

24

22

21

36

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006a Page: 7/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

32. Position head flange (13) on valve adaption (19) and
fasten screws (18)

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

33. Replace O-ring (16) into the piston (11)

34. Hold piston (11) and screw piston rod (12)

35. Replace sliding ring (17) and O-ring (18) from the piston

When holding the piston, make sure the piston is not

scratched or deformed.

Warnings:

12

19

13

18

17

18

11

16

Keeping the World Flowing

37

16.0 Periodic Maintenance

PM-LP-006a Page: 8/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

36. Re-install spring cartridge on piston (11) and fasten screws (15)

INSTRUCTION VALID FOR SPRING DOWN ONLY

37. Replace O-ring (14)

38. Slide spring cartridge (10) piston (11) and piston rod (12)
on head flange (13)

Warnings:

11

10

15

10

11

12

13

14

38

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006a Page: 9/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

39. Replace spacer (9)

INSTRUCTION VALID FOR SPRING DOWN ONLY

36. Replace cylinder tube (8) using suitable lifting tools

37. Replace end flange (6) with O-ring (7)

38. Fasten blind nuts (4) and nuts (5)

Warnings:

9

4

5

Keeping the World Flowing

6

7

8

39

16.0 Periodic Maintenance

PM-LP-006a Page: 10/10

Component: Single-acting actuator Task: LP type 0 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING UP ONLY

40. Slide piston (11) and piston rod (12)

INSTRUCTION VALID FOR SPRING UP ONLY

41. Replace cylinder tube (8) using suitable lifting tools

42. Replace end flange (6) with O-ring (7)

43. Fasten blind nuts (4) and nuts (5)

Warnings:

11

12

4

5

6

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

44. With the help of a wench, screw the stop bolt (3) into the
cylinder flange until length W is achieved

45. Insert the O-ring (2) and, holding the stop bolt (3) with a
wrench, tighten the stop nut (1)

Please refer to page 18 of the present document for the instructions
to regulate the stop bolt position.

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

46. Assemble the control panel, if any, on the central body

47. The actuator must be tested before it is assembled on the valve

48. Place the actuator in a stable position, e.g. on a workbench

49. Connect the pneumatic supply to the actuator and cycle the actuator several times, verify smooth functioning and absence of leakages

50. Check painted parts, if necessary repaint them in accordance with the applicable painting specifications

51. The actuator is now ready to be assembled on the valve

1

2

3

7

8

40

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006b Page: 1/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting clump
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

Description:

Note: the following instructions apply to single-acting actuator unless otherwise specified.

Cut-off power supply and electric power supply (if present) before performing any operation.

Adequate lifting devices and suitable for the weight must be applied by skilled personnel.

Preliminary actions

1. Remove actuator from valve and remove all couplings as well (see Removal from Valve, page 11)

2. Position the actuator on a workbench (if possible) or in a stable position and in a clean and closed area

3. Remove any control equipment (if present). Refer to the project specific documentation

4. Remove pneumatic pipes

APPLICABLE TO TYPE 0 WITH STOP BOLT ONLY (5)

5. Remove cap nut (1) and O-ring (2)

6. Measure length (W)

Warnings:

1

2

W

7. Hold stop bolt (3) with a wrench and loosen and remove
stop nut (4)

8. Remove O-ring (5)

3

4

Keeping the World Flowing

5

41

16.0 Periodic Maintenance

PM-LP-006b Page: 2/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

9. Fully unscrew stop bolt (3)

If the stop bolt is hard to unscrew, pressurise the cylinder and unscrew
stop bolt by 3-4 turns.

Depressurize the cylinder; check if the stop bolt turns freely. If necessary,
repeat the operation.

Do not unscrew the stop bolt completely while the cylinder

is pressurized.

INSTRUCTION VALID FOR SPRING DOWN ONLY

10. Unscrew blind nuts (16) and nuts (6)

11. Remove end flange (7) with O-ring (8)

12. Remove cylinder tube (9) using suitable lifting tools

If as soon as you start unfastening nuts (6) the end flange (7)
suffers a load upwards along with nuts (6), stop and fasten back
the nuts (6). Contact Rotork Service Department.

Warnings:

3

16

6

42

7

8

9

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006b Page: 3/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals

Wrench

Lifting tools

Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

13. Slide spring cartridge (10) piston (11) and piston rod (12)
away from head flange (13)

14. Remove O-ring (14)

Warnings:

10

11

12

14

INSTRUCTION VALID FOR SPRING DOWN ONLY

15. Actuator type 1 – Unfasten screws (15) and remove spring
cartridge away from piston (11)

16. Actuator type 2 – Remove spring cartridge away from
piston (11)

11

13

15

10

Keeping the World Flowing

43

16.0 Periodic Maintenance

PM-LP-006b Page: 4/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING UP ONLY

17. Unscrew blind nuts (16) and nuts (6)

18. Remove end flange (7) with O-ring (8)

19. Remove cylinder tube (9) using suitable lifting tools

If as soon as you start unfastening nuts (6) the end flange (7)
suffers a load upwards along with nuts (6), stop and fasten back
the nuts (6). Contact Rotork Service Department.

Warnings:

16

6

7

8

9

INSTRUCTION VALID FOR SPRING UP ONLY

20. Slide piston (11) and piston rod (12)

11

12

44

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006b Page: 5/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals

Wrench

Lifting tools

Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

21. Hold piston (11) and unscrew piston rod (12)

22. Remove sliding ring (17) and O-ring (18) from the piston

23. Remove O-ring (16)

When holding the piston, make sure the piston is not

scratched or deformed.

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

24. Unfasten screws (19) and remove head flange (13) from the
valve adaption (20)

Warnings:

20

12

17

18

11

16

13

19

Keeping the World Flowing

45

16.0 Periodic Maintenance

PM-LP-006b Page: 6/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

25. Unfasten screws (21) and remove flange (22)

26. Remove O-ring (23) and seals (24) and (25)

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

27. Carefully clean the seals grooves

28. All the removed parts must be thoroughly cleaned, inspected and de-burred as necessary

29. Replace all seals and lubricate them with a grease film

30. Lubricate all sliding parts. Use only recommended grease

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

31. Replace O-ring (23) and seals (24) and (25)

32. Replace flange (22) and fasten screws (21)

Warnings:

21

21

25

25

24

23

22

24

23

22

46

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006b Page: 7/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

33. Position head flange (13) on valve adaption (20) and fasten
screws (19)

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

34. Replace O-ring (16) into the piston (11)

35. Hold piston (11) and screw piston rod (12)

36. Replace sliding ring (17) and O-ring (18) from the piston

Warnings:

13

19

20

When holding the piston, make sure the piston is not

scratched or deformed.

12

16

11

18

17

Keeping the World Flowing

47

16.0 Periodic Maintenance

PM-LP-006b Page: 8/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

37. Actuator type 1 – Re-install spring cartridge (10) on piston (11)
and fasten screws (15)

INSTRUCTION VALID FOR SPRING DOWN ONLY

38. Replace O-ring (14) on head flange (13)

39. Slide spring cartridge (10) piston (11) and piston rod (12)
on head flange (13)

Warnings:

11

15

10

10

12

13

11

14

48

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-006b Page: 9/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

39. Replace cylinder tube (9) using suitable lifting tools

40. Replace end flange (7) with O-ring (8)

41. Fasten nuts (6) and blind nuts (16)

Warnings:

16

6

7

8

9

INSTRUCTION VALID FOR SPRING UP ONLY

40. Slide piston (11) and piston rod (12)

Keeping the World Flowing

11

12

49

16.0 Periodic Maintenance

PM-LP-006b Page: 10/10

Component: Single-acting actuator Task: LP type 1 and type 2 pneumatic cylinder seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING UP ONLY

41. Replace cylinder tube (9) using suitable lifting tools

42. Replace end flange (7) with O-ring (8)

43. Fasten nuts (6) and blind nuts (16)

Warnings:

16

6

7

8

9

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

44. With the help of a wench, screw the stop bolt (3) into the
cylinder flange until length W is achieved

45. Insert the O-ring (2) and, holding the stop bolt (3) with a
wrench, tighten the stop nut (1)

Please refer to page 18 of the present document for the instructions
to regulate the stop bolt position.

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

46. Assemble the control panel, if any, on the central body

47. The actuator must be tested before it is assembled on the valve

48. Place the actuator in a stable position, e.g. on a workbench

49. Connect the pneumatic supply to the actuator and cycle the actuator several times, verify smooth functioning and absence of leakages

50. Check painted parts, if necessary repaint them in accordance with the applicable painting specifications

51. The actuator is now ready to be assembled on the valve

3

50

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-007 Page: 1/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

Description:

Note: the following instructions apply to single-acting actuator unless otherwise specified.

Cut-off power supply and electric power supply (if present) before performing any operation.

Preliminary actions

1. Verify Actuator is in the fail position (single acting) and not pressurized.

2. Remove actuator from valve (see Removal from Valve, page 11)

3. Position the actuator on a workbench (if possible) or in a stable position and in a clean and closed area

4. Remove any control equipment (if present). Refer to the project specific documentation

5. Remove pipes

6. Remove plug (D1)

7. Discharge oil

8. Tighten plug (D1) back in its seat with a wrench

9. Remove hydraulic pipe (P)

10. Unscrew bolts (S) and remove hydraulic pump assembly (3)

Used hydraulic fluid must be disposed of safely.

Warnings:

S

3

P

D1

Keeping the World Flowing

51

16.0 Periodic Maintenance

PM-LP-007 Page: 2/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

11. Hold stop nut (4) with a wrench, unscrew and remove cap nut
(1) with seal washer (2)

12. Measure length (W)

Warnings:

1

2

4

W

13. Loosen the stop nut (4)

52

4

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-007 Page: 3/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

14. Fully unscrew stop bolt (3) and remove seal washer (2)

15. Sustain the hydraulic cylinder adequately

INSTRUCTION VALID FOR SPRING DOWN AND SPRING UP

16. Remove bolts (5)

17. Remove flange (6), O-ring (7) and anti-extrusion ring (8)

18. Remove hydraulic cylinder (9) and tie rods (10)

Warnings:

3

2

5

6

8

7

9

10

Keeping the World Flowing

53

16.0 Periodic Maintenance

PM-LP-007 Page: 4/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING UP ONLY

19. Remove piston (11) and piston rod (12) assembly

INSTRUCTION VALID FOR SPRING UP ONLY

20. Remove sliding rings (13) and O-ring (14)

Warnings:

11

12

13

14

13

INSTRUCTION VALID FOR SPRING DOWN ONLY

21. Unfasten the piston (11) with a pin spanner wrench

54

Installation, Commissioning and Maintenance Manual

11

16.0 Periodic Maintenance

PM-LP-007 Page: 5/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

22. Remove sliding rings (11) and O-ring (12)

INSTRUCTION VALID FOR SPRING DOWN ONLY

23. Unfasten screws (15) and remove flange (16)

24. Remove O-ring (17)

Warnings:

11

12

11

15

16

INSTRUCTION VALID FOR SPRING DOWN ONLY

25. Remove, O-ring (7) and anti-extrusion ring (8)

26. Remove lip seal rings (9)

INSTRUCTION VALID FOR BOTH SPRING DOWN AND SPRING UP

1. Carefully clean the seals grooves

2. All the removed parts must be thoroughly cleaned, inspected and de-burred as necessary

3. Replace all seals and lubricate them with a grease film

4. Lubricate all sliding parts. Use only recommended grease

17

9

8

7

Keeping the World Flowing

55

16.0 Periodic Maintenance

PM-LP-007 Page: 6/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING UP ONLY

27. Replace sliding ring (11) and O-ring (12)

INSTRUCTION VALID FOR SPRING UP ONLY

28. Replace piston (11) and piston rod (12) assembly

Warnings:

11

12

11

11

12

INSTRUCTION VALID FOR SPRING DOWN ONLY

29. Replace O-ring (7) and anti-extrusion ring (8)

30. Replace lip seal rings (9)

56

Installation, Commissioning and Maintenance Manual

9

8

7

16.0 Periodic Maintenance

PM-LP-007 Page: 7/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN ONLY

31. Replace O-ring (17)

32. Replace remove flange (16) and fasten screws (15)

INSTRUCTION VALID FOR SPRING DOWN ONLY

33. Replace sliding rings (11) and O-ring (12)

Warnings:

15

16

17

11

12

11

INSTRUCTION VALID FOR SPRING DOWN ONLY

34. Fasten the piston (11) with a pin spanner wrench

Keeping the World Flowing

11

57

16.0 Periodic Maintenance

PM-LP-007 Page: 8/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR SPRING DOWN AND SPRING UP

35. Position hydraulic cylinder (9) and tie rods (10)

36. Replace O-ring (7) and anti-extrusion ring (8) on flange (6)

37. Lower flange (6) and fasten bolts (5)

38. Assemble seal washer (2) in its correct position and stop bolt (3)
to length W

Warnings:

5

6

8

7

9

10

58

3

2

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-007 Page: 9/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

39. Hold stop bolt with a wrench and tighten stop nut (4)

40. Hold stop nut (4) install seal washer (2) in its correct position
and tighten cap nut (1)

Warnings:

4

1

2

4

Keeping the World Flowing

59

16.0 Periodic Maintenance

PM-LP-007 Page: 10/10

Component: Single-acting actuator Task: Hydraulic cylinder for manual override seals replacement

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

41. Assemble hydraulic pump (3) with its support and tighten
bolts (S)

42. Install pipe (P)

43. Use the hand pump to cycle the actuator and check the
absence of leakages

44. Check painted parts and if necessary paint according to
painting cycle

Warnings:

S

3

P

60

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008a Page: 1/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting clump
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

Description:

Note: the following instructions apply to single-acting actuator unless otherwise specified.

Cut-off power supply and electric power supply (if present) before performing any operation.

Adequate lifting devices and suitable for the weight must be applied by skilled personnel.

Preliminary actions

1. Remove actuator from valve and remove all couplings as well (see Removal from Valve, page 11)

2. Position the actuator on a workbench (if possible) or in a stable position and in a clean and closed area

3. Remove any control equipment (if present). Refer to the project specific documentation

4. Remove pneumatic pipes

5. Remove screw (1) and seal (2)

MH HANDWHEEL

Warnings:

1

2

MHD HANDWHEEL

1

2

6. Remove cap (3), O-ring (4) and
handwheel (5)

MH HANDWHEEL

5

MHD HANDWHEEL

3

4

5

Keeping the World Flowing

3

4

61

16.0 Periodic Maintenance

PM-LP-008a Page: 2/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

7. Remove protective cap (6)

8. Remove grub screws (7)

LP/SD

Warnings:

LP/SU

6

7

6

9. Remove protective tube (8)

LP/SD

7

LP/SU

8

8

62

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008a Page: 3/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

10. Remove grub screws (9)

11. Remove screws (10)

12. Remove protection flange (11)

LP/SD

Warnings:

LP/SU

99

99

10

11

13. Holding stop bolt (12) with a wrench,
unfasten nut (13) with a wrench

12

13

Keeping the World Flowing

63

16.0 Periodic Maintenance

PM-LP-008a Page: 4/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

14. Remove nut (13) and O-ring (14)

INSTRUCTION VALID FOR LP/SU ONLY

15. Unfasten stop bolt (12) with a wrench

Warnings:

13

14

INSTRUCTION VALID FOR LP/SU ONLY

16. Holding stop bolt (12) with a wrench,
fasten screw (14) with a wrench till O-ring
(14) is accessible

17. Remove and replace O-ring (15)

12

14

12

15

64

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008a Page: 5/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR LP/SU ONLY

18. Holding stop bolt (12) with a wrench,
un-fasten screw (14) with a wrench to place
it back in the original position

INSTRUCTION VALID FOR LP/SU ONLY

19. Fasten stop bolt (12) with a wrench

Warnings:

14

12

20. Place a new O-ring (14) and replace nut (13)

12

13

14

Keeping the World Flowing

65

16.0 Periodic Maintenance

PM-LP-008a Page: 6/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

21. Holding stop bolt (12) with a wrench,
fasten nut (13) with a wrench

22. Replace protection flange (11)

23. Fasten screws (10)

Warnings:

12

13

10

11

24. Replace grub screws (9)

66

LP/SD

99

LP/SU

Installation, Commissioning and Maintenance Manual

99

16.0 Periodic Maintenance

PM-LP-008a Page: 7/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

25. Replace protective tube (8)

26. Replace grub screws (7)

LP/SD

Warnings:

LP/SU

8

8

7

27. Replace protective cap (6)

LP/SD

7

LP/SU

6

6

Keeping the World Flowing

67

16.0 Periodic Maintenance

PM-LP-008a Page: 8/8

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder up to size 235

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

28. Replace handwheel (5), O-ring (4)
and cap (3)

29. Replace seal (2) and screw (1)

MH HANDWHEEL

5

MH HANDWHEEL

Warnings:

MHD HANDWHEEL

3

4

5

MHD HANDWHEEL

1

2

3

4

1

2

68

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008b Page: 1/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting clump
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

Description:

Note: the following instructions apply to single-acting actuator unless otherwise specified.

Cut-off power supply and electric power supply (if present) before performing any operation.

Adequate lifting devices and suitable for the weight must be applied by skilled personnel.

Preliminary actions

1. Remove actuator from valve and remove all couplings as well (see Removal from Valve, page 11)

2. Position the actuator on a workbench (if possible) or in a stable position and in a clean and closed area

3. Remove any control equipment (if present). Refer to the project specific documentation

4. Remove pneumatic pipes

INSTRUCTION VALID FOR MH HANDWHEEL ONLY

5. Remove circlips (1) and handwheel (2)

6. Remove key (9)

Warnings:

1

2

1

9

Keeping the World Flowing

69

16.0 Periodic Maintenance

PM-LP-008b Page: 2/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MH HANDWHEEL ONLY

7. Un-fasten screws (3)

8. Remove flange (4) and dust excluder (5)

9. Remove O-rings (15) and (16)

Warnings:

3

5

4

15
16

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

10. Remove 3 screws (7) from flange (8)

70

Installation, Commissioning and Maintenance Manual

8

7

7

16.0 Periodic Maintenance

PM-LP-008b Page: 3/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

11. Remove handwheel (2) and dust excluders (5)

12. Remove flange (8)

Warnings:

5

2

8

5

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

13. Remove keys (9)

9

9

Keeping the World Flowing

71

16.0 Periodic Maintenance

PM-LP-008b Page: 4/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

14. Un-fasten screws (3)

15. Remove flange (4)

16. Remove O-rings (10) and (11)

Warnings:

3

4

10
11

INSTRUCTIONS VALID FOR BOTH MH AND MHD
HANDWHEEL

17. Remove protective tube (6)

LP/SD ACTUATOR

6

LP/SU ACTUATOR

6

72

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008b Page: 5/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

18. Remove keys (12)

19. Un-fasten flange (13)

20. Remove O-ring (14)

LP/SD ACTUATOR

12 12

LP/SD ACTUATOR

Warnings:

LP/SU ACTUATOR

12

12

LP/SU ACTUATOR

13

14

13

14

Keeping the World Flowing

73

16.0 Periodic Maintenance

PM-LP-008b Page: 6/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

21. Lift the manual override shaft to access
O-ring (15) and (16) and remove them

22. Replace O-ring (15) and (16)

23. Replace O-ring (14)

24. Fasten flange (13)

LP/SD ACTUATOR

LP/SD ACTUATOR

Warnings:

LP/SU ACTUATOR

15

15
16

LP/SU ACTUATOR

13

13

14

14

74

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008b Page: 7/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

25. Replace keys (12)

INSTRUCTIONS VALID FOR BOTH MH AND MHD
HANDWHEEL

26. Replace protective tube (6)

LP/SD ACTUATOR

12 12

LP/SD ACTUATOR

Warnings:

6

LP/SU ACTUATOR

12

12

LP/SU ACTUATOR

6

Keeping the World Flowing

75

16.0 Periodic Maintenance

PM-LP-008b Page: 8/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MH HANDWHEEL ONLY

27. Replace dust excluder (5)

28. Replace O-rings (15) and (16)

29. Replace flange (4)

30. Fasten screws (3)

Warnings:

3

5

4

15
16

INSTRUCTION VALID FOR MH HANDWHEEL ONLY

31. Replace key (9)

32. Replace circlips (1) and handwheel (2)

1

2

1

9

76

Installation, Commissioning and Maintenance Manual

16.0 Periodic Maintenance

PM-LP-008b Page: 9/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

33. Clean the grooves and replace O-rings (10)
and (11) into flange (4)

34. Replace flange (4)

35. Fasten screws (3)

Warnings:

3

4

10
11

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

36. Replace keys (9) into the respective grooves

9

9

Keeping the World Flowing

77

16.0 Periodic Maintenance

PM-LP-008b Page: 10/10

Component: Single-acting actuator Task: Manual Handwheel MH and MHD seals replacement

LP/SD and LP/SU actuator, cylinder from size 235 to 385

Equipment, Tools, Materials:

Spare seals
Wrench
Lifting tools
Project documentation

Preliminary Operations: Removal from Valve

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

37. Replace dust excluder (5) and flange (8)

38. Replace handwheel (2) and dust excluder (5)

Warnings:

5

2

8

5

INSTRUCTION VALID FOR MHD HANDWHEEL
ONLY

39. Replace 3 screws (7) into flange (8)

78

Installation, Commissioning and Maintenance Manual

8

7

7

17.0 Part List

Linear pneumatic actuator type 0 spring down

Fig 17.1 Linear pneumatic actuator type 0 spring down

ITEM DESCRIPTION QTY

1 Seal-Washer 4
2 Scraper seal 1
3 Seal 1
4 Sliding ring
5 Bushing 1
6 Silencer 1
7 Nut 1
8 Flange 1

9 Pneumatic cylinder 1
10 Piston 1
11 Flange 1
12 External thrust tube 1
13 Stem 1
14 Adapter flange
15 Valve coupling 1
16 Stop bolt 2
17 Nut 1
18 Spring package 1

●

ITEM DESCRIPTION QTY

19 O-ring
20 O-ring
21 O-ring

1

22 Cylinder O-ring
23 O-ring
24 Piston O-ring
25 Valve adaption 4
26 Tie rod 4
27 Nut Screw 4
28 Blind nut 4
29 Screw 4
30 Screw 4
31 Countersunk screw 2
32 Eyebolt 2
33 Plug (*) 1
34 Seal-Washer (*) 1

(*) present only if items 16, 17, 23 are not present

● Recommended spare par t

Keeping the World Flowing

1

●

1

●

1

●

2

●

1

●

1

●

79

17.0 Part List

Linear pneumatic actuator type 0 spring up

Fig 17.2 Linear pneumatic actuator type 0 spring up

ITEM DESCRIPTION QTY

1 Seal-Washer (*) 1
2 Seal-Washer 4
3 Scraper seal 1
4 Seal 1
5 Sliding ring
6 Bushing 1
7 Silencer 1
8 Screws 4

9 Centring ring 1
10 Flange 1
11 Pneumatic cylinder 1
12 Piston 1
13 Flange 1
14 External thrust tube 1
15 Stem 1
16 Adapter flange 1
17 Valve coupling 1
18 Stop bolt 1

80

Installation, Commissioning and Maintenance Manual

●

ITEM DESCRIPTION QTY

19 Nuts 1
20 Plug (*) 1
21 Spring package 1
22 O-ring

1

23 O-ring
24 O-ring
25 Cylinder O-ring
26 O-ring
27 Piston O-ring
28 Valve adaptor 1
29 Tie rod 4
30 Bolt 4
31 Blind bolt 4
32 Screw 4
33 Countersunk screw 2
34 Eyebolt 2

(*) present only if items 18, 19, 26 are not present

● Recommended spare par t

●

●

●

●

●

●

1
1
1
2
1
1

17.0 Part List

Linear pneumatic actuator type 1 / type 2 spring down

Fig 17.3 Linear pneumatic actuator type 1 / type 2 spring down

ITEM DESCRIPTION QTY

1 Spring 1
2 Adapter flange 1
4 Sliding ring
5 Bushing 1
6 Elbow 1

7 Silencer 1
11 Centring ring 1
21 Piston 1
22 Upper flange 1
23 Flange 1
24 Spring canister 1
25 Cylinder 1
27 Plug 1
28 Stem 1
29 Valve coupling 1
32 Nut 1
33 Blind nut 1
34 Stop bolt 1

1

●

ITEM DESCRIPTION QTY

35 Plug (*) 1
36 O-ring (*)
38 O-ring
39 O-ring
40 O-ring
41 O-ring
42 O-ring
43 O-ring
44 Piston O-ring
45 Valve adaptor 1
46 Tie rod 12
47 Nut 12
48 Blind nut 12
51 Screw 4
52 Screw 2
53 Eyebolt 4

(*) present only if items 32, 33, 34, 41, 42 are not present

● Recommended spare part

●

●

●

●

●

●

●

●

Keeping the World Flowing

1
1
1
1
2
1
2
1

81

17.0 Part List

Linear pneumatic actuator type 1 / type 2 spring up

Fig 17.4 Linear pneumatic actuator type 1 / type 2 spring up

ITEM DESCRIPTION QTY

2 O-ring 1
3 Washer 1
4 Sliding ring
5 Bushing 1
6 Plug 1

8 Adapter flange 1
10 Centring ring 1
15 Spring 1
19 Piston 1
20 Top flange 1
21 Bottom flange 1
22 Cylinder 1
23 Spring canister 1
25 Valve coupling 1
27 Stem 1
30 Nut 1
31 Blind nut 1
32 Stop bolt 1

82

Installation, Commissioning and Maintenance Manual

●

ITEM DESCRIPTION QTY

33 Plug (*) 1
34 O-ring (*)

1

35 Spring
37 O-ring
38 O-ring
40 O-ring
41 O-ring
43 Piston O-ring
44 Valve adaptor 1
45 Tie rod 12
46 Nut 12
47 Blind nut 12
48 Screw 6
49 Screw 2
53 Eyebolt 4

(*) present only if items 30, 31, 32, 40, 41 are not present

● Recommended spare part

●

●

●

●

●

●

●

1
1
1
1
2
1
1

17.0 Part List

Hydraulic cylinder for manual override

Fig 17.5 Hydraulic cylinder for manual override

ITEM DESCRIPTION QTY

1 Hex bolt (**) 4
2 Nut 4
3 Seal washer/O-ring 2
4 Washer 1
5 Piston 1
6 Piston rod seal
7 Sliding ring
8 O-ring

9 Bushing 1
10 Plug 1
11 Piston seal

●

●

●

●

ITEM DESCRIPTION QTY

12 End flange 1
13 Head flange 1
14 Piston rod 1
15 Cap nut 1

16 Stop bolt 1
2
2
1

1

18 Back up ring

19 Tie rod (**) 4

20 Cylinder tube 1

21 Stop nut 1

(**) Number of tie rods and nut depending on cylinder size

● Recommended spare part

●

Keeping the World Flowing

1

83

17.0 Part List

Mechanical manual override MH

Fig 17.6 Mechanical manual override MH

ITEM DESCRIPTION QTY

1 O-ring
2 Handwheel 1
3 Setting dowel 1
4 Nut 1
5 Bearing 1
6 Cap 1
7 Back plate 1
8 O-ring
9 O-ring

10 Nut 1

84

Installation, Commissioning and Maintenance Manual

●

●

●

ITEM DESCRIPTION QTY

1

1
1

11 Nut 1
12 Screw 1
13 Protective tube 1
14 Washer 1
15 Screw 6
16 Unscrewing flange 1
17 Flange 1
18 Protective cap 1
19 Jackscrew 1

● Recommended spare part

17.0 Part List

Mechanical manual override MH

Fig 17.7 Mechanical manual override MH

ITEM DESCRIPTION QTY

1 Dust excluder
2 Bearing 1
3 Handwheel 1
4 Protective tube 1
5 Flange 1
6 Flange 1
7 Spindle nut 1
8 Lead screw 1

9 Ring nut 1
11 Plate 1
12 O-ring

●

●

ITEM DESCRIPTION QTY

1

1

13 O-ring
14 Cap 1
15 Nut 1
16 Nut 1
17 Washer 1
18 Key 2
20 Plate 1
21 Circlip 2
22 Screw 8

● Recommended spare part

●

Keeping the World Flowing

1

85

17.0 Part List

Mechanical manual override MHD

Fig 17.8 Mechanical manual override MHD

ITEM DESCRIPTION QTY

1 Dust excluder
2 Bearing 1
3 Wheel hub 1
4 Screw 3
5 Knob 1
6 Handwheel 1
7 Protective tube 1
8 Flange 1

9 Flange 1
10 Spindle nut 1
11 Lead screw 1
13 Ring nut 1

86

Installation, Commissioning and Maintenance Manual

●

ITEM DESCRIPTION QTY

2

14 Plate 1
15 O-ring
16 O-ring
17 O-ring
18 Nut 2
19 Nut 1
20 Washer 1
21 Plate 1
22 Screw 8
23 Key 2

● Recommended spare part

●

●

●

2
1
1

18.0 Grease & Hydraulic Oil Specification

In general, there is no need to lubricate the actuator because

its mechanism is lubricated for life. The standard grease

for Rotork fluid powered actuators is shown below. If an

alternative was specified and/or supplied, please refer to the

job specific documentation.

18 .1 Grease

Use following grease or equivalent to lubricate the manual

override jackscrew and seals of pneumatic cylinders.

Manufacturer: SHELL

Trade name: GADUS S5 V25Q

NLGI grade: 2.5

Colour: Clear Brown

Penetration, density, viscosity
Viscosity of oil at 40 °C (ASTM D445):
Viscosity of oil at 100 °C (ASTM D445):

Temperature
Drop point (IP396):

18.2 Hydraulic Oil

Below is the standard oil specification for Rotork fluid powered

actuator hydraulic manual override and hydraulic cylinders

working at temperature between -20 °C and +100 °C for ATEX

and non-ATEX application.

25 cST

4.8 cST

180 °C

Manufacturer: MOBIL

Trade Name: DTE 10 EXCEL 32

ISO Viscosity Grade: 32

Viscosity, ASTM D 445
cSt @ 40 °C
cSt @ 100 °C

Viscosity Index, ASTM D 2270 164

Brookfield Viscosity ASTM D 2983, cP @ -20°C 1090

Brookfield Viscosity ASTM D 2983 cP @ -30°C 3360

Brookfield Viscosity ASTM D 2983 cP @ -40°C 14240

Tapered Roller Bearing (CEC L-45-A-99), %Viscosity Loss 5

Density 15° C, ASTM D 4052, kg/L 0.8468

Copper Strip Corrosion, ASTM D 130, 3 hrs @ 100 ºC 1B

Rust Characteristics, ASTM D 665B Pass

FZG Gear Test, DIN 51534, Fail Stage 12

Pour Point, °C, ASTM D 97 -54

Flash Point, °C, ASTM D 92 250

Foam Sequence I, II, III, ASTM D 892, ml 20/0

Dielectric Strength, ASTM D877, kV 49

Acute Aquatic Toxicity (LC-50, OECD 203) Pass

32.7

6.63

Keeping the World Flowing

87

18.0 Grease & Hydraulic Oil Specification

Below is the standard oil specification for Rotork fluid
powered actuator hydraulic manual override and hydraulic
cylinders working at temperature between -40 °C and
+100°C for ATEX and non-ATEX application.

Manufacturer: MOBIL

Trade Name: DTE 10 EXCEL 15

ISO Viscosity Grade: 15

Viscosity, ASTM D 445
cSt @ 40 °C
cSt @ 100 °C

Viscosity Index, ASTM D 2270 158

Brookfield Viscosity ASTM D 2983 cP @ -40 °C 2620

Tapered Roller Bearing (CEC L-45-A-99), %Viscosity Loss 5

Density 15 °C, ASTM D 4052, kg/L 0.8375

Copper Strip Corrosion, ASTM D 130, 3 hrs @ 100 ºC 1B

Pour Point, °C, ASTM D 97 -54

Flash Point, °C, ASTM D 92 182

Foam Sequence I, II, III, ASTM D 892, ml 20/0

Dielectric Strength, ASTM D877, kV 45

Acute Aquatic Toxicity (LC-50, OECD 203) Pass

15.8

4.07

Below is the standard oil specification for Rotork fluid
powered actuator hydraulic manual override and hydraulic
cylinders working at temperature between -60°C and
+90°C for ATEX and non-ATEX application.

Manufacturer: TECCEM

Trade Name: SynTop 1003 FG

ISO Viscosity Grade: 3

Viscosity, ASTM D 445
cSt @ -40 °C
cSt @ -55 °C
cSt @ 40 °C

Pour Point, °C, ASTM D 97 -88 °C

Flash Point, °C, ASTM D 92 140 °C

Density 20° C, kg/L 0.86

73

2.6

3.2

An alternative oil may have been specified for your
application. Please refer to the job specific documentation.

88

Installation, Commissioning and Maintenance Manual

Keeping the World Flowing

89

www.rotork.com

A full listing of our worldwide sales and
service network is available on our website.

Rotork plc
Brassmill Lane, Bath, UK

tel [phone]
fax [phone]
email [e-mail]

PUB020-014-00
Issue 07/19

Rotork is a corporate
member of the Institute
of Asset Management

All Rotork F luid System s actuator s are manufac tured unde r a third par ty accredited ISO9 001 qualit y
assurance p rogramme. A s we are contin ually deve loping our pr oduct s, their des ign is subje ct to change
without notice.

The name Rot ork is a regis tered trade mark. Rotor k recognis es all regis tered trade marks. P ublished an d
produced i n the UK by Rotor k. POW TG0719