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: rfs.internationalservice@rotork.com
Rotork, Via Padre Jaques Hamel 138B,
Porcari, Lucca, IT. Tel: +39 0583-222-1
Rotork plc, Brassmill Lane, Bath, UK. Tel +44 (0)1225 733200
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.
4
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.
6
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
Keeping the World Flowing
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
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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
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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.
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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
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