Sempell Pneumatic Drive Type A 160 IOM, Sempell-EN Manuals & Guides

SEMPELL

Pneumatic Actuator Type A 160

Operating Instructions

Design according to TO.270.07
Observe design data on the nameplate!
Foruseofacontrol device STE 4 or STE 5 observe
corresponding operating instruction!

Attention!

This operating instruction is only valid in
connection with the operating instruction
of the pertaining safety valve.

Contents

1 Danger and Warning Indications 2

2 Description 2

3 Operation 2

3.1 Storage Rules 3

3.2 Compressed-Air Connection 3

3.3 Pressure Test 3

3.4 Commissioning 3

4 Inspection and Maintenance Works 4

5 Disassembly 4

5.1 Danger and Warning Indications 4

5.2 Tools 4

5.3 Utilities 4

5.4 Removing the Pneumatic Actuator A160 4

5.5 Dismantling the Pneumatic Actuator A160 4

5.6 Removal of the Valve Bonnet by Means of the Pneumatic Actuator A160 5

6 Assembly 5

6.1 Assembly of the Valve Bonnet 5

6.2 Assembly of Pneumatic Actuator A160 5

6.3 Mounting the Pneumatic Actuator A160 5

6.4 Adjusting the Pneumatic Actuator A160 6

7 Drawings 7

7.1 Assembly drawing A160 7

7.2 Safety valve with Pneumatic Actuator A160 8

8 Determination of the Characteristics 9

8.1 Calculations 9

8.2 Characteristics Safety Valves VSE / VSR 10

8.3 Characteristic Safety Valves Series S DIN 10

www.valves.emerson.com

Emerson reserves the right to change the content without
notice MA.270.07.0905 E

SEMSH-0067-EN-1310

Pneumatic Actuator Type A 160

Operating Instructions

1 Danger and Warning Indications

Attention!

In each case observe the danger and warning indications of the operating instruction of the
pertaining safety valve.

Danger for Persons and Materials

• Use pneumatic actuator only for the intended purpose.

• Additional mountings and modifications to pneumatic actuator and assemblies are only allowed
with our approval. The same applies for foreign accessories or spare parts.

• Observe installation instructions.

• Adhere to the rules for prevention of accidents and safety instructions related to plant.

Avoidance of Danger

Working at valves only by skilled personnel and with special work permit.

Attention!

Observe and adhere to the precautions marked in the sections of this operating instruction.

For disassembling the system wait for official permission. The system has to be pressureless.
After each action control ready-to-operation state of actuator and safety valve. Control all sealing
points.

Exclusion of Liability

Sempell GmbH does not accept liability when a/m regulations, instructions and warning indications
are not observed and adhered to.

Application Limits

It is only allowed to use the actuators
according to the details of this operating
instruction and according to the
parameters and application cases agreed
in the delivery contract (see nameplate).

2 Description

Application

The pneumatic actuator A160 is designed for the supplementary loading of safety valves and is
triggered by control device STE4 or STE5.
The working pressure difference of the safety valve can be reduced by supplementary loading.
Thereby, the margin between set pressure of safety valve and working pressure of the system is
smaller than 10% of the set pressure.
The supplementary loading (normally 20 – 30 % of the spring force of the spring loaded safety
valve) results in higher tightness at the valve seat. Opening and closing pressure differences can be
reduced. The safety valve also can be opened below the set pressure by means of the pneumatic
actuator.
To specify the supplementary loading see chapter 8.

Functioning

In normal operating state, compressed air in the space above the piston produces the
supplementary loading. The piston of the pneumatic actuator is connected with the spindle of the
safety valve.
The set pressure is adjusted by the pressure switches of the control device (STE4 or STE5). Exceeds
the system pressure the adjusted set pressure the supplementary loading is released. At the same
time lifting air is applied to the space below the piston. The safety valve opens.
If the system pressure drops below the adjusted closing pressure, the lifting air will be released and
the supplementary loading applied again. The safety valve closes.

3 Operation

3.1 Storage Rules

To preclude damages during loading and unloading move the valves cautiously. Levers and
other parts are unsuitable as lifting points. The transport shall preferable take place by crane or
transport pallet.
At delivery the outsides of all steel parts of the safety valve are supplied with a coat of paint
except the welding edges and gasket surface(s).
All connections are closed by suitable caps.
In this state the safety valve with pneumatic actuator can be stored in closed, dust-free and dry
rooms lying on a pallet without difficulties. Time of storage about six months.
Storage of more than six months asks for disassembly and visual check of the inner parts of the
safety valves. A weather-protected outside storage is not allowed.

Emerson

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Pneumatic Actuator Type A 160

Operating Instructions

• For spare parts out of elastomers
(O-rings, scraper rings, rod and piston gaskets) additionally apply:
Temperature: The temperature of the storage shall be between 0°C and 25°C since otherwise
a hardening of the material and so a shortening of durability will follow. Shield heating
elements and lines in heated storeroom so that no direct heat irradiation arises. The distance
between the heat source and the stored goods has to be 1 m at least.
Moisture: To prevent the formation of condensate, avoid moist storerooms. A relative humidity
of below 65 % is at best.
Lighting: The elastomers are to be protected from direct sun light and from strong artificial
light with a high ultraviolet content. Therefore cover the windows of the storerooms with a red
or orange (in no case blue) paint.
Ozone: Protect elastomers against ozone (formation of cracks and embrittlement). The
storeroom may not contain ozone generating systems (fluorescing sources of light, mercury
vapor lamps, electric motors, etc.).
Oxygen: Protect elastomers from draught by storage containers. Oxygen causes cracking and
embrittlement.
If these requirements are guaranteed for elastomers the storage time is about 5 years.

• For spare parts out of steel:
Store the parts in closed, dust-free and dry rooms so that damages do not occur.

3.2 Compressed-Air Connection

The connections of the lifting and loading air lines are lateral to the pneumatic actuator. The
pertaining compressed-air hoses (attached to delivery) enable the tension-free connection to
the pneumatic actuator.
The compressed-air hoses for pneumatic actuator have tube fittings including ferrule with
which pipe OD Ø 22 x 2 can be fastened.

IMPORTANT

• Clean the lifting and loading air lines by blowing out with compressed air before connection.

• Take care that the controlled air lines are correct assigned:

- Loading air line at the upper connection of the pneumatic actuator

- Lifting air line at the bottom connection of the pneumatic actuator

3.3 Pressure Test

Attention!

The lifting of the safety valve must be prevented.

Either flange off safety valve and close supply line with a blind flange or mechanically block the
valve. In case of welded-in safety valves a pressure test plug can be used.

Attention!

For blocked safety valve the test pressure can be up to 1.5x the set pressure without
consulting Sempell.

Screw on cap (160.14) upside down to the piston rod (160.06) and sturdily tighten with
hexagonal screw (160.16) to the cylinder cover (160.02) so that the disc is blocked in closed
position.

Attention!

In case of removed cap (160.14) take care that no dirt or parts fall into the cylinder.
Restore and control ready-to-operation state after the pressure test.

3.4 Commissioning

• Check functional readiness of actuator.

• Prove duly interaction of safety valve and control device STE4 or STE5. Check according to
operating instruction of the pertaining control device.

Emerson

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Pneumatic Actuator Type A 160

Operating Instructions

4 Inspection and Maintenance Works

Inspection intervals depending on frequency of response and operating conditions, e. g. annually,
under severe conditions twice a year. Keep record on performed works.

At commissioning and at each inspection

• After the first pressure charge and each disassembly:

• Check each sealing point on tightness. Replace if leaky.

At disassembled pneumatic actuator

• Treat sliding guides, fittings, gaskets and threads with an assembling lubricant.

5 Disassembly

5.1 Danger and Warning Indications

Attention!

Take work order and wait for official permission
Control if the pneumatic actuator is pressureless.
Before disassembling switch off power supply, loosen plug or disconnect cable.

5.2 Tools

• fixed spanner 10 - 36 mm

• socket wrench 6, 8 mm

• screwdriver 8 mm

• retaining ring pliers for outer rings

• flatnose pliers

• side cutting pliers

• hammer

• punch Ø 2,5; 3; 4 mm

• seal wire

• lead seal

• lead-sealing pliers

• marking gage

5.3 Utilities

• Degreasant: Kaltron 113MDS/113MDK/113MDI35. Frigen 113TR-T.

• Freon PCA/TF/T-P35/TA. Isopropyl alcohol with acetone, mixture 1:1, white spirit.

• Lubricant for assembly (MoS2): Molykote-Spray, Dow Corning, Munich.

• Lubricant for assembly (Colloidal-Graphite) for parts in contact with the medium:
DAG156 Acheson, Dornstadt. Neolube 1, 2, Lubricant Consult, Maintal.

• Only to facilitate assembling:
Lubricating grease for bearings, spindle threads, screws and the like:
Molykote-BR2plus (≤ 80 °C); BG20 (> 80 °C), Dow Corning, Munich;
Barrierta L55/2 (> 120 °C), Klüber, Munich, Mobilgrease Spec., Mobil Oil

• O-ring grease: DOW Corning, Munich

5.4 Removing the Pneumatic Actuator A160

Measure and record the position of the coupling (71). Loosen allen bolts (72) and turn the
coupling (71) so far from the spindle until the piston (160.05) in the cylinder rests. Remove lead
seal. Bend up locking plates (68) and loosen hexagonal screws (67). Carefully lift pneumatic
cylinder a little (maximum piston stroke) and turn off coupling (71) completely from the spindle.
Horizontally remove coupling (71) and lift off pneumatic cylinder.

Attention!

When using Barrierta L55/2 carefully
clean components with white spirit
180/200 or Klüberalfa XZ3-1 before
assembling as otherwise loss of lubricity
is possible. Never mix Barrierta L55/2
with other lubricants.

5.5 Dismantling the Pneumatic Actuator A160

Disassemble pneumatic actuator only if necessary.
Unscrew cap (160.14). Loosen screw bolts (160.11) and lift off upper cylinder cover (160.02).
Straighten locking plate (160.08) and loosen hexagonal nut (160.07). Remove piston (160.05).
In doing so, strongly hold cylinder (160.03) and lift off with the piston (160.05) together. If
required, remove cylinder (160.03) from the piston (160.05). For re-assembly use device.
Straighten locking plates (70) and loosen hexagonal screws (69). Remove cooling spacer (66).

Remark:

At pneumatic actuator A160.1 (cylinder diameter 125 mm) piston and piston rod are of one
piece.

Emerson

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160.14

160.16

Pneumatic Actuator Type A 160

Operating Instructions

5.6 Removal of the Valve Bonnet by Means of the Pneumatic Actuator A160

Attention!

Further disassembly of the removed complete valve bonnet is not allowed.

For the inspection and grinding of the valve seat, it is not necessary to completely disassemble
the safety valve. For this purpose, the complete valve bonnet with locked spring can be
removed.

Attention!

The pressure spaces of the pneumatic piston must be pressure-released. Please check:
Pressure indicator at the manometer “Loading” and “Lifting” in the control unit shows 0 bar.

Loosen hexagonal nuts at the screwing (160.21) and remove pneumatic hoses. Unscrew ring
screw (160.22) and hexagonal screws (160.16).
Remove cap (160.14), unscrew the eye bolt and place the screw the cap onto the piston rod
(160.06). Place the hexagonal screws (160.16) into the threaded holes of the cap (160.14) so
that the cap (160.14) is supported by the cylinder cover (160.02) of the actuator. Thus the spring
of the safety valve is locked. The hexagonal screws (160.16) shall be tightened securely by hand
only.

Clearance 0.5 - 1 mm

Attention!

At safety valves (VSE/VSR series V, SOH) and at higher set pressures the valve spring must be
blocked by means of the spring lock nut (98).

Screw down spring lock nut (98) until a clearance of 0.5 – 1 mm is left between pressure screw
of the safety valve and spring lock nut (98). Loosen bonnet nuts, remove valve insert.
For further disassembly see corresponding operating instruction of the safety valve.

6 Assembly

6.1 Assembly of the Valve Bonnet

• Insert complete valve bonnet and tighten with bonnet nuts.

• If now - due to rework or replacement of the safety valve disc - the hexagonal screws
(160.16) are too tight or too loose, detach lock nut and adjust adjusting screw in such
manner that the hexagonal screws (160.16) sturdily rests again. Thus the same set pressure
is obtained as before. Secure adjusting screw with lock nut (see operating instruction of the
safety valve).

• Loosen hexagonal screws (160.16) and turn cap (160.14) from the piston rod (160.06). Put
cap (160.14) into the correct position on the cylinder cover (160.02) again and tighten with
hexagonal screws (160.16). Assemble ring screw (160.22) and O-ring (160.23).

6.2 Assembly of Pneumatic Actuator A160

• Slide cylinder (160.03) over the ring (160.10) into the piston (160.05), if possible with the
device. Insert piston rod (160.06) in the piston (160.05), tighten with hexagonal nut (160.07)
and secure it by bending the locking plate (160.08).

• Move cylinder cover (160.01, 160.02) with O-rings (160.04), rod guide rings (160.13, 160.20)
and Turcon scraper ring (160.19) on the piston rod (160.06) and tighten with screw bolts
(160.11) and hexagonal nuts (160.12).

• Mount cap (160.14) and O-ring (160.15). Fasten cooling spacer (66) with hexagonal screws
(69) and secure it by bending the locking plates (70). Hang in coupling (71).

• The Turcon scraper ring (160.19) in the lower cylinder cover (160.01) is fixed with a supporting
disc (160.17) and a retaining ring (160.18).

6.3 Mounting the Pneumatic Actuator A160

• Put pneumatic cylinder with coupling (71) carefully on the spindle and screw coupling (71)
on the spindle. In doing so, continue lowering the pneumatic cylinder. Fasten cooling spacer
(66) with hexagonal screws (67) and secure it by bending the locking plates (68).

• Move coupling (71) into the registered position and clamp with Allen bolts (72).

Emerson

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Pneumatic Actuator A 160

Operating Instructions

6.4 Adjusting the Pneumatic Actuator A16

Attention!

In any case correctly adjust pneumatic actuator A160. An incorrect adjusted actuator may
impair the functioning of the safety valve.
The actuator must be pressureless.

Procedure

1. Make sure that the pneumatic actuator is pressureless.

2. Remove cap (160.14).

3. Loosen Allan bolts (72).

4. Move piston (160.05) into uppermost position up to the stop of the cylinder cover (160.02)
(by turning coupling (71)).

5. Measure dimension A.

6. Determine dimension B
[B = A - (valve lift - 1)]

7. Pull piston (160.05) downwards by means of coupling (71) until dimension B is reached.

8. Restore mechanical joint between coupling and valve spindly by tightening the allan
bolts(72).

Ca. 2 mm

At type 160.14 ca. 4 mm

Adjustment of coupling

valve lift minus 1 mm

Spindle position upper piston stop

Valve lift minus 1 mm

Important

During the adjustment the piston rod must rest upon the coupling!

Valve spindle lowest position
(safety valve closed)

reserves the right to change the contents without notice page 6

Emerson

160.1

160.1

160.0

160.1

7 Drawings

7.1 Assembly drawing A160

Pneumatic Actuator A 160

Operating Instructions

160.22

160.16

160.14

160.20

160.04

160.03

160.05

160.10

160.11

160.04

160.01

70

69

160.23

160.25

Adjustment of coupling

valve lift minus 1 mm

160.21

5

2

Spindle position upper
piston stop

2

160.21

2

160.13

160.19

160.17

160.18

66

67
68

71

72

160.07

160.08

160.09

160.06

160.26

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Emerson

Pneumatic Actuator Type A 160

Operating Instructions

7.2 Safety valve with pneumatic actuator A160

Emerson reserves the right to change the contents without notice page 8

Pneumatic Actuator Type A 160

Operating Instructions

8 Determination of the Characteristics

By means of the recommended pneumatic actuator all safety valves (see chapter 8.1 and 8.2)
obtain a supplementary loading of at least 30 %. The safety valves can be opened at a system
pressure of 85 % of the set pressure p with the pneumatic actuators. This applies for a control air
pressure of 6 bar.

8.1 Calculations
Supplementary loading

Supplementary loading is the additional sealing force (closing force) either percentage from the
adjusted spring force or referring to the set pressure according to the formula:

Z [%] =

Terms:
supplementary loading = Z, constant 1 = K1,
control air pressure [bar] = pk, set pressure [bar] = p

Required system pressure for compulsory opening of the safety valve below the set
pressure

The minimum pressure p (syst. A) at which the set pressure of the valve can be checked, is
calculated as follows:

p (sys.A) = p – K2 x pk

The minimum pressure p (syst. H), at which the valve can be compulsorily opened completely
up to the lift stop, approximately results from:

p (syst.H) = p –

Terms:
constant 2 = K2, control air pressure [bar] = pk, set pressure [bar] = p

Example

Safety valve VSE orifice letter F (see section 8.1)
set pressure p = 130 bar
control air pressure pk = 5 bar

From table:
pneumatic actuator type A160.1.22
constant K1 = 15.1

K1 x pk

p

x 100%

K2 x pk

2

K2 = 13.9

Z =

p (sys. A) = 130 – 13.9 x 5 = 60.5 bar

p (syst. H) = 130 –

Emerson reserves the right to change the contents without notice page 9

15.1 x 5

130

x 100% = 58.1%

13.9 x 5
2

= 95.3 bar

Pneumatic Actuator Type A 160

Operating Instructions

8.2 Characteristics Safety Valves VSE / VSR

The pneumatic actuators are recommended for a supplementary loading of at least 30% at
6 bar control air pressure. Opening of the safety valve at 85% of the set pressure or less are
possible at 6 bar control air pressure. Pneumatic actuators for higher supplementary loadings
are also available.

Orifice Max. set Pneumatic Constant Drive with return spring

letter pressure drive required below

pmax [bar] type K1

A 200.0 A160.1.14.BO

500.0 A160.1.14.BO

B 200.0 A160.1.14.BO

450.0 A160.1.22.BO

C 200.0 A160.1.14 34.90 32.20 40.0

450.0 A160.1.22 34.90 32.20 –

D 90.0 A160.1.14 19.60 18.00 26.0

315.0 A160.1.22 19.60 18.00 –

E 90.0 A160.1.14 19.60 18.00 26.0

315.0 A160.1.22 19.60 18.00 –

F 80.0 A160.1.14 15.10 13.90 20.0

280.0 A160.1.22 15.10 13.90 –

G 63.0 A160.1.14 11.00 10.20 16.0

224.0 A160.1.22 11.00 10.20 –

H 56.0 A160.1.14 8.30 7.60 11.0

167.0 A160.1.22 8.30 7.60 –

200.0 A160.2.22 21.20 20.60 –

J 133.0 A160.1.22 6.30 5.80 10.0

180.0 A160.2.22 16.20 15.70 –

K 100.0 A160.1.22 4.70 4.40 8.0

160.0 A160.2.22 12.10 11.70 –

L 67.0 A160.1.22 3.50 3.30 6.0

140.0 A160.2.22 9.10 8.80 –

M 50.0 A160.1.22 2.60 2.40 4.0

100.0 A160.2.22 6.70 6.50 –
N 71.0 A160.2.42 5.00 4.80 5.0
P 56.0 A160.2.42 3.70 3.60 3.5
Q 40.0 A160.2.42 2.80 2.73 2.8
R 31.5 A160.2.42 2.00 1.98 2.0
S 22.4 A160.2.42 1.50 1.46 1.5
T 16.0 A160.2.66 1.06 1.03 1.0
U 12.5 A160.2.66 0.77 0.75 0.7
V 9.0 A160.2.66 0.62 0.60 0.6
W 7.1 A160.2.66 0.45 0.44 0.5

1)

34.90 32.20 40.0

1)

65.90 60.70 –

1)

34.90 32.20 40.0

1)

34.90 32.20 –

2)

K2 3) p [bar]

Notes

1) Pneumatic actuator only for supplementary
loading

2) Factor for the determination of the
supplementary loading

3) Factor for the determination of the set
pressure

8.3 Characteristic Safety Valves Series S DIN

The pneumatic actuators are recommended for a supplementary loading of at least 30% at
6 bar control air pressure. Opening of the safety valve at 85% of the set pressure or less are
possible at 6 bar control air pressure. Pneumatic actuators for higher supplementary loadings
are also available.

Orifice Max. set Pneumatic Constant Drive with return spring

letter pressure drive required below

pmax [bar] type K1

D 414.0 A160.1.08.BO
E 414.0 A160.1.08.BO
F 345.0 A160.08.14 20.90 14.50 35.0
G 255.0 A160.08.14 12.60 8.90 20.0
H 102.0 A160.08.14 7.20 5.80 14.0

190.0 A160.1.14 17.50 16.10 –

J 56.0 A160.08.14 4.30 3.50 10.0

186.0 A160.1.14 10.50 9.70 –

K 20.0 A160.08.22 3.00 2.50 6.0

160.0 A160.1.22 7.40 6.80 –

L 20.0 A160.08.22 2.00 1.62 5.0

103.0 A160.1.22 4.90 4.50 –
M 76.0 A160.1.22 3.80 3.50 6.0
N 69.0 A160.1.22 3.20 2.90 4.0
P 69.0 A160.2.42 5.70 5.50 5.0
Q 42.0 A160.2.42 3.30 3.22 3.0
R 25.0 A160.2.42 2.30 2.24 2.0
T 22.5 A160.2.66 1.41 1.37 1.3

Emerson

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1)

28.60 23.10 40.0

1)

28.60 23.10 40.0

2)

K2 3) p [bar]

Notes

1) Pneumatic actuator only for
supplementary loading

2) Factor for the determination of the
supplementary loading

3) Factor for the determination of the set

pressure