Shafer RAP H10-Accumulator Seal Replacement Instructions Manuals & Guides

RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI (Parts & Service: Accum Seal) 05/09/11
Accumulator Seal Replacement Instructions
RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
Accumulator Service
direction (See Figure 1) until the upper
WARNING: THIS COMPONENT CONTAINS
HIGH PRESSURE HYDRAULIC FLUID AND NITROGEN GAS. EXERCISE CAUTION WHEN PERFORMING ANY TYPE OF MAINTENANCE. WEAR PROPER SAFETY ATTIRE INCLUDING SAFETY GLASSES.

A. Disassembly

1. Close the Power Oil Isolation Valve.
2. Isolate the Accumulator to be repaired on both the hydraulic and nitrogen side.
3. Open the System By-Pass Valve and drain the hydraulic fluid and pressure from the Accumulator.
4. Vent the nitrogen pressure from the top of the accumulator piston.
5. Remove the Accumulator from the skid.
Note: If the hydraulic power unit
head is free of the cylinder.
CAUTION: The accumulator upper
head weighs approximately 65 pounds (30 kilograms). Use caution as to not damage the threads when removing the upper head from the cylinder.
9. To remove the Lower Head, install two 3/4-10 x 4" (100 mm) long hex head cap screws into the lower head. Place a pry-bar between the two cap screws and turn in a counter-clockwise direction (See Figure 2) until the lower head is free of the cylinder.
CAUTION: The accumulator lower
head weighs approximately 100 pounds (45 kilograms). Use caution as to not damage the threads when removing the lower head from the cylinder.
contains more than one accumulator, all other accumulators may be returned to service once the accumulator to be repaired has been removed from the skid.
6. Place the Accumulator horizontally on a workbench and secure.
7. Remove all piping components connected to the upper and lower heads. Do Not Remove Plugs From Heads.
10. If the Accumulator is equipped with a Piston Stop, remove it through the end of the cylinder that held the upper head. Take precautions to protect the accumulator cylinder and piston stop from damage. Retain the nylon guides located in each end of the piston stop (total of 6).
11. Remove the Piston from the
accumulator through the end of the cylinder that held the upper head. If the piston is at the bottom of the cylinder, push towards the top. Take
8. To remove the Upper Head, install two 5/8-18 x 4" (100 mm) long hex head cap screws into the upper head. Place a pry-bar between the two cap screws and turn in a counter-clockwise
precautions to protect the accumulator cylinder and piston from damage. The center of the piston contains a ½-13 tapped hole that can be used to install an eyebolt or standard bolt, to ease in the removal of the piston from the
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
Accumulator Service
cylinder. Use caution to not damage
the threads when removing the piston from the cylinder.
12. With all components removed, visually inspect the accumulator cylinder for any damage, such as grooves or nicks.
13. Remove and discard all seals and back-up rings from the accumulator components.
5. By hand, begin screwing the Lower Head into the Cylinder turning the Lower Head in a clockwise direction. A pry-bar may be used after the Lower Head has started correctly (See Figure
2).
Note: The Cylinder is tapered to allow
the seals to start into the cylinder bore without shearing them.
14. Clean all components, and inspect for damage to interior surfaces. Give close attention to the seal grooves.
6. Continue screwing in the Lower Head until it is tight against the cylinder wall (See Figure 3).

B. Reassembly

7. Insert the Piston next. Use the Accumulator Sub-Assembly drawing
At this time the new seals are to be installed and the accumulator re-
(Figure 4) as a guide for the location of the T-Seal and wear bands.
assembled. For reassembly, a thread lubricant such as “NEVER-SEEZ®” and a, PTFE/petroleum base all-purpose, grease such as “ACCROLUBE®” will be required.
1. Install the Lower Head first. Using the Accumulator Sub-Assembly drawing Figure 4 as a guide, place the Back­Up Ring into the seal groove first. Carefully install the O-Ring next to the Back-Up Ring.
8. Carefully place the T-Seal into its groove. Place the T-Seal’s back-up rings next to the seal as shown and apply grease to the seal.
9. Apply grease to the wear band groove.
10. Place the wear band into the groove and grease again. (This will help prevent the bands from coming off the piston, when it is being placed into the accumulator cylinder)
CAUTION: Do not overstretch the “o-
ring” or push the “o-ring” across the threads of the accumulator lower head.
11. Carefully insert the Piston into the Cylinder. Do not allow the seals to scrape against the internal threads of the Cylinder.
2. Apply grease to the O-Ring and Back­Up Ring.
12. As the Piston enters the Cylinder, it may require a “gentle nudge” to get the T-Seal started into the bore. Use a
3. Apply thread lubricant to the external threads of the Lower Head.
4. Carefully insert the Lower Head into the Cylinder. Do not allow the seals in the Lower Head to scrape against the
soft or rubber mallet to strike the piston. Do Not Use A Metal Hammer. Strike the Piston side to side, across the diameter, to avoid binding of the Piston.
internal threads of the Cylinder.
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
Accumulator Service
13. If a Piston Stop is used, it must be inserted next. Place grease in and around the holes that hold the nylon guides (this will help hold them in place). Place the nylon guides into the holes and insert the Piston Stop into
18. By hand, begin screwing the Upper Head into the Cylinder turning the Upper Head in a clockwise direction. A pry-bar may be used after the Upper Head has started correctly (See Figure
1).
the Cylinder.
Note: The Cylinder is tapered to allow
Note: The piston may have to be
pushed lower into the Cylinder to accommodate the length of the Piston Stop
14.
Install the Upper Head. Using the Accumulator Sub-Assembly drawing (Figure 4) as a guide, place the Back­Up Ring into the seal groove first. Carefully install the O-Ring next to the Back-Up Ring.
19. Continue screwing in the Upper Head until it is tight against the cylinder wall (See Figure 3).
The procedure is now complete and the Accumulator may be re-installed on the skid. It is recommended that a hydrostatic test be performed to check the integrity of
the seals to start into the cylinder bore without shearing them.
the seals before replacing the accumulator
CAUTION: Do not overstretch the “o-
ring” or push the “o-ring” across the threads of the accumulator lower head.
15.
Apply grease to the O-Ring and Back­Up Ring.
16. Apply thread lubricant to the external threads of the Upper Head.
17. Carefully insert the Upper Head into the Cylinder. Do not allow the seals in the Upper Head to scrape against the internal threads of the Cylinder.
on the skid. If no hydrostatic test is performed, use clean compressed air to push the Piston to the Lower Head.
After the Accumulator has been re-installed on the skid and all connections have been made, the nitrogen should be introduced into the Accumulator first. After the nitrogen has filled the top of the Accumulator, the hydraulic supply may be established (this will allow the system to act as if oil volume had been discharged from the hydraulic power unit)
For problems, which cannot be handled by
our customers, we have qualified service
personnel available upon request. If the need should arise, please feel free to contact:
EMERSON PROCESS MANAGEMENT
VALVE AUTOMATION, INC.
2500 Park Avenue West
Mansfield, Ohio 44906 Telephone: (419) 529-4311 Fax: (419) 529-3688
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
Accumulator Service
Figure 1: Accumulator Upper Head
Figure 2 Accumulator Lower Head
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
05/09/11
Accumulator Service
Head to Cylinder Joint Figure 3
Head to Cylinder Joint Figure 3
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
05/09/11
Grease upper and lower heads
with ACCROLUBE grease until
grease comes out air bleed hole on
opposite side of accumulator
Accumulator Service
open
Accumulator Sub-Assembly Figure 4

Pc Qty. Description

01 1 Upper Head
02 1 Lower Head
03 1 Piston
04 1 Cylinder
05 2 Wear Ring 79007-023
06 2 O-ring 568-269-479-70
07 2 Back-up Ring 8-269-N2067-90
08 2 Grease Fitting
09 1 “T” Seal B001-TP067-N4182A
10 2 Plastic Cup
11 1 Piston Stop (if required)
12 6 Nylon Guide (if required)
cant to threads
Lubri
¾-10 4-Holes 02 07 06 04 05 09 03 11 12 08 10 01 5/8-18 2 Holes
Keep
top and bottom
½-13 1 Hole Air Bleed Hole
Accumulator Sub-Assembly Figure 4
¾ NPTF ¼ NPTF Apply “NEVER SEEZ” Straight Thread
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RAP H10: Accumulator Seal Replacement Instructions
HPU/ASRI
05/09/11
Accumulator Service
Please visit our website for up to date product data.www.shafervalve.com
The contents of this publication are presented for informational purpose only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifications of such products at any time with out notice.
Trademarks owned by other companies that are referred to in our product literature include: NEVER-SEEZ® and ACCROLUBE®
www.ShaferValve.com
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