OPERATION & MAINTENANCE MANUAL
MODEL APP PISTON PNEUMATIC ACTUATOR
TABLE OF CONTENTS I.
Introduction. . . . . . . . . . .
..................
................
3
II.
Actuator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III.
Actuator Technical Specication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IV.
Actuator Size, Dimensions, Weight & Volme . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V.
Ordering Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VI.
Control Pressure Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VII.
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VIII.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IX. X.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
XI.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XII.
Actuator Valve Sizing Chart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XIII.
Actuator Assembly Drawing/Bonnet Bill of Material . . . . . . . . . . . . . . . . . . . . . . 14
XIV.
Field Removal and Replacement of the Model APP Piston and Retainer Nut Seal . . . . . 15
XV.
Field Removal and Replacement of Piston Actuator Top Shaft PolyPak™ Seal. . . . . . . . 17
XVI.
Main Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
XVII.
Diaphragm Actuator Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
XVIII. Array Bonnet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 XIX
Array Bonnet to Gate Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XX.
Actuator to Bonnet & Gate Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
XXI.
Setting the Gate Valve Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
XXII.
Field Removal and Replacement of Bonnet Seal Packing . . . . . . . . . . . . . . . . . . . 26
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 XXIII. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 XXIV. Testing & Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 XXV.
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
XXVI. Product Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
page 2
INTRODUCTION The Model APP actuator is a piston type, pneumatically-powered gate valve actuator designed to operate a “fail-closed” or “fail-open” safety valve. It is ideally suited for wellhead safety valve applications, ow lines, header valves and gathering lines. It can also be used for casing relief valve and storage valve applications. The Model APP actuator is lightweight, easy to maintain and engineered to ensure years of trouble-free service in the harshest of environments and operating conditions on land or off-shore. The Model APP actuator can be delivered as an actuated valve assembly ready to be placed in service or as an actuated bonnet assembly ready to mount on another manufacturer’s valve.
ACTUATOR OPERATION Array model APP Pneumatic Piston Actuators are designed to operate Array Fail-Safe Bonnet Assemblies used on gate valves and move them from their Fail-Safe positions. The thrust required to do this is created by application of pneumatic control pressure to the actuator inlet port. Pneumatic pressure acting on the piston overcomes the thrust created by the forces of the valve pressure acting on the bonnet stem and gate friction due to any pressure differential acting on the valve gate and spring. It will open fail-closed gate valves. Removal of this pressure allows the bonnet stem forces to return the valve gate to it’s fail-safe position. The actuator return spring provides the required force to overcome dynamic seal friction and the weight of moving parts when NO pressure exists on the valve. When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft will depend on whether the valve is fail-closed and how much pressure differential is present across the valve gate. Fail-closed valves initially open with a sudden “jerk” as the gate “cracks” open and the pressure differential is reduced. This is normal and does not damage the valve or hinder its function. The severity and travel of this rapid motion depends on the amount of pressure differential across the gate valve. The greater the differential, the more rapid the motion for a longer amount of total valve stroke. The remainder of the actuator motion should be smooth and uniform. Upon removal of control pressure from actuator mounted on fail-closed valves, the motion should be smooth throughout the entire stroke. Speed of this action depends on many factors such as how fast a differential builds across the gate, is a locally mounted quick exhaust valve being used to exhaust the control pressure and the size of the actuator and valve. As a general rule, the faster the control pressure is removed from the actuator the quicker it will close.
page 3
ACTUATOR TECHNICAL SPECIFICATION
1.
Applicable Gate Valve Bores
113/16" thru 71/16"
2.
Applicable Gate Valve W.P.
2M thru 15M
3.
API Classication
6A
4.
Trim (API 6A Material Class)
BB
5.
Temperature Classication
P -20° to 180°F (-29°C to -82° C)
6.
Maximum Operating Pressure
170 psi / 12 Bars
7.
Maximum Test Pressure
255 psi / 18 Bars
8.
Pressure Relief Device Setting (Bronze)
170 psi @ 130° F (12 Bars @ 54° C)
9.
Actuator Volume
See chart on page 5
10.
Weight
See chart on page 5
11.
Dimensions
See chart on page 5
page 4
MODEL APP PISTON PNEUMATIC ACTUATOR ACTUATOR SIZES, DIMENSIONS, WEIGHT & VOLUME A
B
C
page 5 D
E
F
G
in
mm
in
mm
in
mm
in
mm
in
mm
in
mm
1300 X 020
23⁄4 – 8
3.75
95
19.25
488
6.93
176
13.99
355
13.64
346
2.34
59
1300 X 030
23⁄4 – 8
4.37
111
19.87
504
6.97
177
13.99
355
13.64
346
2.34
59
1300 X 040
23⁄4 – 8
5.04
128
23.52
597
8.15
207
13.99
355
16.61
422
5.29
134
1300 X 050
23⁄4 – 8
6.82
173
33.84
859
8.89
225
13.99
355
23.72
602
8.74
221
1300 X 060
2 ⁄4 – 8
7.82
198
34.84
885
8.89
225
13.99
355
23.72
602
8.74
221
1800 X 030
3"– 8
4.82
122
28.70
729
8.89
225
19.27
489
21.01
533
8.24
209
1800 X 040
3"– 8
5.82
147
29.70
754
8.89
225
19.27
489
21.01
533
8.24
209
1800 X 050
3"– 8
6.75
171
30.64
778
8.89
225
19.27
489
24.01
609
8.24
209
1800 X 060
3"– 8
7.98
202
34.60
878
8.89
225
19.27
489
24.01
609
8.24
209
1800 X 070
3"– 8
8.04
204
34.60
878
12.19
309
19.27
489
24.02
610
7.88
200
2000 X 030
3"– 8
4.37
111
33.22
843
12.18
309
21.53
546
25.57
649
7.03
178
2000 X 040
3"– 8
5.25
133
34.10
866
12.19
309
21.53
546
25.57
649
7.03
178
2000 X 050
3"– 8
6.37
161
37.22
945
12.18
309
21.53
546
25.57
649
7.03
178
2000 X 070
3"– 8
7.91
200
38.76
984
12.18
309
21.53
546
25.57
649
7.03
178
3
B
C
A
F
G
D E
ACTUATOR SIZE
SWEPT VOLUME
WEIGHT
in3
cm3
lbs
kgs
APP 1300 x 020
460
7539
258
117
APP 1300 x 030
526
8621
276
126
APP 1300 x 040
658
10,785
284
130
APP 1300 x 050
790
12,948
306
139
APP 1300 x 060
982
16,095
335
152
APP 1800 x 030
1210
19,832
525
239
APP 1800 x 040
1442
23,634
550
250
APP 1800 x 050 APP 1800 x 060
1637 1895
26,830 31,060
579 625
263 284
APP 1800 x 070
2002
33,140
640
291
APP 2000 x 030
1471
24,110
688
313
APP 2000 x 040
1784
29,240
718
327
APP 2000 X 050
2097
34,370
793
361
APP 2000 X 070
2723
44,630
839
513
Note: Swept volumes represent the maximum actuator stroke.
ORDERING INFORMATION The following information should be provided when requesting a quote or issuing a purchase order to Array Products for an APP Pneumatic Piston Actuator.
Actuator Model of Actuator:_______________________________________________________________________________ Size of Actuator: ________________________________________________________________________________ Actuator Control Pressure Availability: ______________________________________________________________ Special Requirements: • Testing _______________________________________________________________________________________ • Coating_______________________________________________________________________________________ • Certication / Specication_______________________________________________________________________
Bonnet / Gate Valve Gate Valve Bore Size:_____________________________________________________________________________ Rated Working Pressure of Gate Valve:______________________________________________________________ Temperature Rating: _____________________________________________________________________________ Material Class: _________________________________________________________________________________ PSL Rating:_____________________________________________________________________________________ PR Rating:______________________________________________________________________________________ Interface Drawing Availability:______________________________________________________________________
Accessories Fusible Lock Open Cap: __________________________________________________________________________ Fusible Manual Override: _________________________________________________________________________ Hydraulic Override: ______________________________________________________________________________ Stem Protector (Clear) (Metal):_____________________________________________________________________ Electronic Switches Proximity: ____________________________________________________________________
page 6
MODEL APP PISTON PNEUMATIC ACTUATOR CONTROL PRESSURE EQUATIONS
page 7
VALVE WORKING PRESSURE
VA LV E
B O RE S I Z E
3 , 0 0 0 P S I
5,000PS I
1 0 ,0 0 0 P SI
A P P 1 3 0 0 x 0 3 0
134 psi .013 x wp + 3 psi
72 psi .007 x wp + 2 psi
39 psi .012 x wp + 3 psi
63 psi .012 x wp + 3 psi
113⁄16
APP 1800x030
AP P1300x030
21⁄16
AP P1300x030
2 ⁄16 9
AP P 1 3 0 0 x 0 3 0
88 psi .017 x wp + 3 psi
3 ⁄8 31⁄16
APP1300x 030
173 psi .017 x wp + 3 psi A P P 1 8 0 0 x 0 3 0
92 psi .009 x wp + 2 psi
1
A P P 1 8 0 0 x 0 3 0
54 psi .017 x wp + 3 psi
AP P1300x030
APP1300x 030
143 psi .014 x wp + 3 psi
APP 1300x030
198 psi .013 x wp + 3 psi APP 1800x030
107 psi .007 x wp + 2 psi
APP 1800x030
122 psi .008 x wp + 2 psi
82 psi .008 x wp + 2 psi
AP P 1 3 0 0 x 0 3 0
1 5 ,0 0 0 P SI
76 psi .024 x wp + 4 psi
AP P1300x040
112 psi .036 x wp + 4 psi
41⁄16
178 psi .058 x wp + 4 psi
AP P1300x030
124 psi .024 x wp + 4 psi APP1800x040
APP1800x 030
122 psi .012 x wp + 3 psi 103 psi
.012 x wp + 3 psi
.010 x wp + 2 psi
AP P 1 3 0 0 x 0 4 0
AP P1800x040
137 psi .009 x wp + 2 psi APP 2000x030
107 psi .007 x wp + 2 psi
APP 2000x030
153 psi .010 x wp + 3 psi
APP 2000x030
63 psi
184 psi .036 x wp + 4 psi
APP 1800x030
APP2000x 040
153 psi .015 x wp + 3 psi
97 psi .019 x wp + 2 psi APP2000x040
AP P1300x050
51⁄8
AP P1800x050
71⁄16
93 psi .030 x wp + 2 psi
AP P1800x070
78 psi .015 x wp + 2 psi
APP1800x050
152 psi .030 x wp + 2 psi AP P 2 0 0 0 x 0 5 0
123 psi .024 x wp + 3 psi
164 psi .054 x wp + 2 psi
APP2000x070
135 psi .044 x wp + 3 psi
Note: The designed values provided above only apply to actuators manufactured for Array gate valves and are provided for reference only. (SEE NOTES ON NEXT PAGE)
CONTROL PRESSURE EQUATIONS page 8
NOTE: • All actuator sizing complies with API 6A 10.16.3.7 (latest edition) force output valve requirements. • PSI is required pressure to crack valve @ maximum working pressure. • Sizing equation includes spring load. • APP Actuator size, description and bore size at maximum working pressure. • PSI number is total of equation and spring load to open gate valve @ maximum working pressure. • Control pressure equation x valve working pressure + total spring load. When calculating control supply for the APP use this equation.
ACTUATOR SELECTION PROCEDURE Determine gate valve specications such as size, maximum rated working pressure, projected shut-in pressure and maximum ow line pressure.
DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY Determine maximum ow line pressure in gate valve. What is the available hydraulic pressure supply at site? Multiply the maximum ow line pressure by the matrix equation and add the remaining number of psi for the total hydraulic pressure to be used to open gate valve.
APP SIZING CHART page 9
113/16 Nominal Gate Valve 170 160 150 140 130
Cp 030
120 110
13 = .0
p+ xw
3p
si
P 1300 x AP
110 90 80
1800 APP
70 60 50
C x 030
p=.
x 007
wp
i) s (p e r u s s e r P l o r t n o C r o t a u t c A d e r i u q e R
si +2p
40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
l a i t n e r e f if D ll u F t a e v l a V n e p O o t
15
Valve Working Pressure (WP) x 1000 psi
21/16 Nominal Gate Valve 170 160 150 140 130 120 110 110 90
P AP
80 70 60 50
0 130
40
30 x0
C
3 .01 p=
xw
00 13
3 p+
30 x0
= Cp
.01
4x
+ wp
3p
si
0 Cp x 03 000 2 P AP
psi
8 = .0 0
x wp
+2p
si
i) s (p e r u s s e r
P l o r t n
o C r o t a u t c A d e r i u q e R
APP
30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Valve Working Pressure (WP) x 1000 psi
l a i t n e r e f f i D ll u F t a e lv a V n e p O o t
APP SIZING CHART page 10
29/16 Nominal Gate Valve 170 160 150 140 130 120 110 100 90
AP
80
0x 30 P1
p= 030 C
7 .01
x
+ wp
3p
si
2 ps
p+
A PP
70
180
0
AP P
60 50
0 x 03
200
Cp
= .009 x w
p 30 C 0x0
= .0 0
7xw
i i) s (p e r u s s e r P l o r t n o C r o t a u t c A d e r i u q e R
p si p+3
40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
l a i t n e r e f if D ll u F t a e v l a V n e p O o t
15
Valve Working Pressure (WP) x 1000 psi
31/8 – 31/16 Nominal Gate Valve 170 160 150 140 130 120 110 100 90
P AP
80 70
0 13
0
x
0 03
Cp
=
.0
24
x
p w
+
4
ps
i
12 = .0
p+ xw
2p
.010 Cp p= 30 C 0 x 030 800 0x P1 200 P AP AP
si p xw
+3
psi i) s (p e r u s s e r
P l o r t n
60
o C r o t a u t c A d e r i u q e R
50 40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Valve Working Pressure (WP) x 1000 psi
l a i t n e r e f f i D ll u F t a e lv a V n e p O o t
APP SIZING CHART page 11
41/16 Nominal Gate Valve 170 160 150 140 130 120 110
.
100 90 80 70
P A
60 50
P
00 13
x
0
40
5 03
x
p w
+
i ps
4
9 01 =.
p= C
P AP
xw
2 p+
p 040 040 C 0x x 00 0 2 0 P 18 AP
i ps
= Cp
.01
5
p+ xw
3p
si
i) s (p e r u s s e r P l o r t n o C r o t a u t c A d e r i u q e R
40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
l a i t n e r e f if D ll u F t a e v l a V n e p O o t
15
Valve Working Pressure (WP) x 1000 psi
51/8 Nominal Gate Valve 170 160 150 140 130 120 110 100 90 80 70 60
A
50
P P
1
0 3
0
x
5 0
0
p C
=
5 .0
8
x
p w
P AP
+
4
s p
0 18
i
0
x
0 05
A
PP
C
p
=
3 .0
00 20
x
0
x
p w
0 05
+
Cp
2
=
ps
i
24 .0
x
w
p
+
3
ps
i
i) s (p e r u s s e r
P l o r t n
o C r o t a u t c A d e r i u q e R
40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Valve Working Pressure (WP) x 1000 psi
l a i t n e r e f f i D ll u F t a e lv a V n e p O o t
APP SIZING CHART page 12
71/16 Nominal Gate Valve 170 160 150 140 130
.0
120 110 100 90 80 70 60 50
A
P P
1
8
0
0
x
A
0
7
0
P P
5
4
x
2
0
0 0
7 0
p
i s
4
p= C
x
p w
+
2
0
p C
4
x
p w
+
3
p
si
= .0
i) s (p e r u s s e r P l o r t n o C r o t a u t c A d e r i u q e R
40 30 20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Valve Working Pressure (WP) x 1000 psi
l a i t n e r e f if D ll u F t a e v l a V n e p O o t
ACTUATOR VALVE SIZING CHART PROCEDURE page 13
1. To select the proper actuator size and control pressure you must rst determine the gate valve bore size and the maximum working pressure of the valve. 2. Now determine the maximum owing and shut in pressure for production. 3. Determine the available hydraulic control supply pressure at location. 4. Using the appropriate gate valve bore chart, nd the y-axis location and draw a vertical line to the top of the chart.
31/8 – 31/16 Nominal Gate Valve 170 160 150 140 130 120 110 100 90
P AP
80 70
0 13
0
x
03
0
Cp
=
.
4 02
x
p w
+
4
ps
i
12 = .0
p+ xw
2p
.010 Cp p= C 030 0 x 03 800 0x P1 200 P AP P A
si p xw
+3
psi
60 S IX
50 40 30
A Y
20 10 0 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
)i s p ( e r u s s e r P l o r t n o C r
l ia t n e r e f f i D ll u
t o a u t c A d e r i u q e R
F t a e v l a V n e p O o t
15
Valve Working Pressure (WP) x 1000 psi
5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point denes the minimum required actuator control pressure to open the gate valve.
Example: A valve pressure of 8,100 psi requires a piston actuator pneumatic control pressure of 99.2 psi to open gate valve (APP 1800 x 030). See control pressure equation matrix on page 7.
PARTS LIST page 14 #
DESCRIPTION
1
Top Shaft
2
Seal Retainer (AK)
3
Retainer Ring (AK)
4
Rod Wiper (AK)
5
Polypak™ Seal (AK)
6
Wear Bearing (AK)
7
Top Plate Assembly
8
Shear Ring
9
O-Ring (AK)
10
Retainer Nut
11
O-Ring (AK)
12
O-Ring (AK)
13
Wear Bearing (AK)
14
Piston Assembly
15
O-Ring (AK)
16
Spring Retainer Plate
17
Spring
18
Down Stop
19
Lock Ring
20
Bonnet Ring
21
Pressure Relief Device (AK)
22
Housing Bolts (AK)
1 4
22 8 21 9
15 11 16
14
17
12 13
Cylinder
25
Actuator Assy ID Tag (NS)
18
26
Drive Screw (NS)
41
27
AttachmentBolt
28
Locking Screws (AK)
29
Cam Clamp
Caution Tag (NS, AK)
19
10
Lower Plate Assembly
Washer (AK)
6
7
24
31
5
3
23
30
2
24
23
27
32 28 20
29
BONNET
32
Packing Retainer
33
O-Ring (Inner) (BK)
34
O-Ring (Outer) (BK)
35
Test Fitting
36
Polypak™ Seal (BK)
37
Bonnet Stem
38
Bonnet
39
Bonnet Assembly ID Tag (NS)
40
Drive Screw (NS)
41
Drift Shims
30
33
37 34
36
35
38
(NS) = Not Shown (AK) = Actuator Repair Kit Items
Parts list includes items in a typical bonnetassembly. Some differences may exist in bonnets for valves
(BK) = Bonnet Repair Kit Items
manufactured by companies other than Array Products. In those cases the specic differences are usually limited to the design of the bottom of the bonnet and operating stem.
FIELD REMOVAL AND REPLACEMENT OF THE MODEL APP PISTON AND RETAINER NUT SEALS 1. Disconnect power source going into actuator side nipple (1/2–14 NPT) inlet. Caution:Be sure to disconnect pneumatic quick exhaust. (The piston or diaphragm in the quick exhaust may not shift totally thereby trapping a small amount of air pressure in top case). This could be injurious to personnel. 2. Do not disconnect the pressure relief device 3. If electric proximity switches are installed remove them from top of actuator. Do not injure or mishandle. Be aware when removing bracket so as to correctly install properly later. Caution:All wire leads must be replaced carefully. 4. Remove all lock open devices such as caps, fusible caps and overrides (mechanical and fusible). Caution:If fusible or mechanical lock open cap is installed on the Actuator, prior to any disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will prevent injury to personnel. After pressurizing Actuator, unscrew fusible or mechanical cap and set aside. 5. The location of and access to the piston actuator will determine the disassembly procedure. In some locations the piston actuator should be removed from the site and repaired in a different location. 6. To replace the piston o-ring seal when the actuator is installed on the wellhead follow instructions below. Caution:Remove quick exhaust valve from the control line to actuator. 7. Make sure safety valve is in fully closed position with bonnet stem backseated. Check (Test Fitting #35) on bonnet to insure stem is backseated and not leaking. 8. Thread the 3/4-10 UNC lifting eye into the threaded end of top shaft. Tighten securely. 9. Using a box end wrench remove 4 (Housing Bolts #22) and (Washers #30) from (Top Plate Assembly #7) surface. 10. Remove split (Lock Ring #19) from groove located at stop surface of (Top Plate Assembly #7), set aside. 11. Using a small at blade screwdriver remove (Shear Ring # 8) from recess groove in housing. Visual access may be hindered by dirt, grime etc..remove before extracting shear ring. 12. Remove (Top Plate Assembly #7) from (Cylinder #23). The top plate can be removed by using the two lifting lugs located on the top plate and the lifting eye ring threaded into the top shaft. The top plate can be removed as a single part. You can use the (Top Shaft #1) and lifting eye ring to remove the (Piston Assembly #14) and (Top Plate Assembly #7) together. Be prepared to handle the weight as both components are heavy. 13. If piston and top plate are removed as a single unit, place both on a at surface. Lift top plate off of piston and set aside. 14. Thoroughly clean piston top plate and piston. Check for wear marks on piston (Wear Bearing #13) and (Cylinder #23) I.D. Remove any grime or particles that may be in cylinder I.D. 15. Push (Top Shaft #1) thru (Piston Assembly #14) sub assembly. Inspect O.D. sealing surface. Clean and set aside. 16. Remove (O-Ring #12) from O.D. seal groove of (Piston Assembly #14). Clean O.D. seal groove on (Piston Assembly #14). Inspect seal groove for surface nish and dings or nicks. Clean and inspect bad o-ring for abrasions, cuts and tears. Lubricate O-ring groove lightly, set aside. 17. Remove (Retainer Nut #10) from (Piston Assembly #14). Use a 14" pipe wrench and rotate in a counterclockwise direction. Clean inspect and remove any shavings from pipe wrench and nut.
page 15
18. Install three o-rings on (Retainer Nut #10). Install (O-Ring #11) into face seal. Lightly grease. Install (O-Ring #15) 2 each, into bore. Slightly grease. Clean threads on piston. Lightly brush on “Neverseez™” to threads on piston. Thread (Retainer Nut #10) into bore of (Piston Assembly #14). Grease area on top of piston for face seal o-ring. Tighten securely with pipe wrench. Remove any metal particles from piston made by pipe wrench jaws. 19. Insert (Top Shaft #1) thru (Retainer Nut #10) bore. Wipe of excess grease from top shaft. 20. With piston sub assembly on a at surface, install (O-Ring #12). Lightly grease o-ring and piston O.D. groove. After o-ring is installed grease o-ring and groove generously. 21. Lift the (Piston Assembly #14) by the (Top Shaft #1) and center over the opening of the (Cylinder #23). Push down evenly. Caution:Do not force or hit piston with hammer to force piston into cylinder bore. Make sure piston is positioned level in top of cylinder. 22. Lift (Top Plate Assembly#7) up and down onto cylinder and piston assembly. Caution:Be careful to center (Top shaft #1) with the seal bore of (Top Plate Assembly #7). With both hands, lower the top plate onto the cylinder. At approximately 2” distance from the top of the cylinder allow the top plate to slide down and engage the piston assembly. The movement will force piston into cylinder bore concentrically. The weight of the top plate assembly will push the top piston assembly into the bore smoothly. Once the top plate assembly has stopped on the cylinder shoulder push down forcibly to insure proper seating of shoulder. Note: If top plate is tight tting into top of cylinder and has not seated use a dead blow hammer, plastic or brass to tap plate into position. 23. Install (Shear Ring #8) into cylinder groove. Be sure to seat ring properly. Install (Lock Ring #19) into groove space. The ring must seat properly with not high spots. If the (Lock Ring #19) will not install properly, remove shear ring and clean and inspect groove. Then re-install shear ring. 24. Install (Housing Bolts #22) and (Washers #30) into tapped holes in top plate. Tighten securely to 25 to 30 ft lbs. 25. Reinstall a lifting eye in the top shaft tapped hole. Pick up the pneumatic piston actuator assembly and remove the spring. Set spring aside. 26. If this is a new actuator assembly, it must be adapted to a gate valve adapted for with the appropriate bonnet assembly for testing as an SSV. Otherwise, it can be mounted to a test xture with stroke capabilities for API 6A testing as an actuator. 27. The completed piston actuator assembly must be thoroughly inspected. Apply (Caution Tag #31) to top plate next to a 12-NPT Port. 28. Apply (Actuator Assembly ID Tag #25) to lower case. Use 2 each (Drive Screws #26). 29. Test according to API 6A latest edition. This testing excludes hydrostatic testing of the actuator. 30. After testing is complete thread (Pressure Relief Device #21) into (Top Plate Assembly #7). 31. Use Teon tape or Teon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate. 32. All assembly and testing must be performed by certied personnel. 33. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will be serialized and documented by certied personnel.
page 16
MODEL APP REMOVAL AND REPLACEMENT OF PISTON ACTUATOR TOP SHAFT POLYPAK™ SEAL 1. Disconnect power source going into actuator side nipple (1/2-14 NPT) inlet. Caution:Be sure to disconnect pneumatic quick exhaust. (The piston or diaphragm in the quick exhaust may not shift totally thereby trapping a small amount of air pressure in top case). Removing actuator from bonnet assembly when air pressure is still in actuator can be injurious to personnel. 2. Do not disconnect the pressure relief device. 3. If electric proximity switches are installed remove them from top of actuator. Do not injure or mishandle. Be aware when removing bracket so as to correctly install properly later. Caution:All wire leads must be replaced carefully. 4. Remove all lock open devices such as fusible caps and overrides (mechanical and fusible) and set aside. Caution:If a fusible or mechanical lock open cap is installed on top of the piston actuator, prior to any disassembly pressure actuator to full open position to release upward thrust load on cap. This operation will prevent injury to personnel. After pressurizing actuator unscrew fusible or mechanical cap and set aside. 5. Remove (Retainer Ring #3) from top of threaded boss and set aside. 6. Remove (Seal Retainer #2) from bore of threaded boss. Inspect (Wiper Ring #4) installed internally into (Seal Retainer #2). Clean both parts and set aside. 7. Remove top shaft (Polypak™ Seal #5) and replace. Inspect old Polypak™ for wear marks. 8. Clean top machined seal bore in top threaded boss. Inspect for burrs and dings in sealing bore. 9. Clean and inspect exposed portion of top shaft. Look for dings, marks and any surface imperfection that cause a pressure leak. 10. Install (Polypak™ Seal #5). Grease bore generously prior to installation. Push down to stop on shoulder. O-ring must be facing downward toward gate valve / bonnet end. 11. Install (Seal Retainer #2) and (Wiper Ring #4). 12. Install (Retainer Ring #3) into groove. Clean and inspect groove prior to re-assembly. Lock retainer ring securely. 13. Re-install pressure control line and quick exhaust valve into side mounted (1/2-14 NPT) nipple. Tighten securely. Pressurize piston actuator and check for leaks prior to installation of accessories.
page 17
APP MAIN ACTUATOR ASSEMBLY The following outlines the assembly of the Pneumatic Piston Actuator in rst sub assemblies and then into a nal assembly. All item numbers refer to the Bill of Material items. Caution:It is imperative that when assembling the Pneumatic Piston Actuator, the assembly be free of all
ying debris.
PROCEDURE 1. Inspect the (Lower Plate Assembly #24) bore for surface imperfections. Check I.D. and O.D. for cleanliness, dings, burrs or scratches. Set aside on clean at surface. 2. Place the housing on at surface with the bore facing up. Thoroughly clean the entire housing and lightly lubricate the bore with assembly lubricant. 3. Clean the (Top Shaft #1). Verify that the shaft is clean and free of scratches and dents. Grease lightly and set aside. 4. Inspect the (Retainer Nut #10). Clean the three o-ring grooves. Check the grooves for burrs, dings and sharp edges. 5. Install three o-rings into the (Retainer Nut #10). Be sure all grooves are clean prior to installation. Install (O-Ring #15) 2 each, into I.D. grooves. Install (O-Ring #11) 1 each into the face groove. Grease all three o-rings generously after assembly. Set Retainer Nut aside. 6. Examine the (Piston Assembly #14) for proper coating. Inspect for dings, Burrs and sharp edges. Look at the surface nish on the o-ring groove. Thoroughly clean the piston; remove all foreign debris from the threads. Lubricate entire part lightly. 7. Place the piston on a clean, at surface. The o-ring groove should be facing upward. Install the (O-Ring #12) into the piston groove. Lightly grease the (O-Ring #12) prior to installation. After installation of the o-ring, grease more generously. 8. Install the (Wear Bearing #13) into the outer diameter groove of the (Piston Assembly #14). Be sure that the two ends meet correctly and there is no overlap pressure. Grease installed wear bearing generously. 9. With (Piston Assembly #14) located on a at clean surface, Install the (Retainer Nut #10) by rotating by hand in a clockwise direction will stopping. Engage the outer diameter of the retainer nut with 14” pipe wrench in a clockwise direction. Tighten securely. 10. Place the (Piston Assembly #14) on its side. Slide the (Top Shaft #1) through the bore of the (Retainer Nut #10). Push till shoulder of top shaft stops on nose of retainer nut, life entire assembly up by top shaft and place on a at clean surface. Set aside. 11. Place the (Top Plate Assembly #7). Inspect the entire part. Check for sharp edges, scratches, dings and burrs. Thoroughly clean the (Top Plate Assembly #7) , remove all debris. 12. Inspect and clean the top Boss bore. Check for sharp edges and burrs on threads. Check entire part for coating and surface nish. Check (1/2" NPT) threads (2 places) on top of plate. Check o-ring groove for cleanliness, no burrs, dings or sharp edges. Lightly grease the o-ring groove. 13. Install (O-ring #9) into groove of (Top Plate Assembly #7) and lightly grease. 14. Install (Wear Bearing #13) into bore of (Top Plate Assembly #7) , make sure ends do not overlap and stick up preventing piston from sliding into cylinder. 15. Install (Polypak™ Seal #5) into (Top Plate Assembly #7) threaded Boss bore. Make sure o-ring energizer is facing downward toward bonnet/valve end. Push Polypak™ to stop on shoulder. 16. Install (Wiper Ring #4) into I.D. bore of (Seal Retainer #2).
page 18
17. Install (Seal Retainer #2) into bore of top plate. Push down to contact (Polypak™ Seal #5). page 19
18. Install (Retainer Ring #3) into groove at top of threaded boss. Use a blade screwdriver to seat retainer ring into groove. 19. Set assembled (Cylinder #23) aside. 20. Place the (Shear Ring #8) and (Lock Ring #19) together on a at plane. Set the (Lower Plate Assembly #24) in the middle of the two rings. These two rings will be installed after housing is in place. 21. Inspect the (Lower Plate Assembly #24) check the coating surface and nish and holes for sharp edges. Clean the lower plate thoroughly. 22. When assembling the APP Pneumatic Actuator without a bonnet place the (Spring #17) into the cylinder of the valve lower plate. Center spring. 23. Lift the (Cylinder #23) over and down onto shoulder of (Lower Plate Assembly #24). Allow cylinder to stop on shoulder of lower plate. Rotate cylinder by hand to check for proper alignment. 24. Install (Shear Ring #8) into bottom side of (Lower Plate Assembly #24) Ring must snap into groove. The t must be snug. 25. Install (Lock Ring #19) into groove adjacent to (Shear Ring #8). Ring must seat properly with no stick up or high spots. Install (Housing Bolts #22), 4 each and (Washers #30), 4 each. Tighten securely. 26. Grease (Cylinder #23) generously the entire length. Lift the (Piston Assembly #14) by the (Top Shaft #1) and center over the opening of the (Cylinder # 23). Push down evenly. Caution:Do not force or hit piston with hammer to force piston into cylinder bore. 27. Lift (Top Plate Assembly #7) up onto cylinder and piston assembly. Caution:Be careful to center (Top Shaft #1) with the seal bore of (Top Plate Assembly #24). With both hands, lower the top plate onto the cylinder. At approximately 2" distance from the top of the cylinder allow the top plate to slide down and engage the piston assembly. The movement will force piston into cylinder bore concentrically. The weight of the top plate assembly will push the top piston assembly into the bore smoothly. Once the top plate assembly has stopped on the cylinder shoulder push down forcibly to insure proper seating of shoulder. 28. Install (Shear Ring #8) into cylinder groove. Be sure to seat ring properly. Install (Lock Ring #19) into groove space. The ring must seat properly with not high spots. If the (Lock Ring #19) will not install properly, remove shear ring and clean and inspect groove. Then re-install shear ring. 29. Install (Housing Bolts #22) and (Washers #30) into tapped holes in top plate. Tighten securely to 25 to 30 ft lbs. 30. Reinstall a lifting eye in the top shaft tapped hole. Pick up the pneumatic piston actuator assembly and remove the spring. Set spring aside. 31. If this is a new actuator assembly, it must be adapted to a gate valve adapted for with the appropriate bonnet assembly for testing as an SSV. Otherwise, it can be mounted to a test xture with stroke capabilities for API 6A testing as an actuator. 32. The completed piston actuator assembly must be thoroughly inspected. Apply (Caution Tag #31) to top plate next to a 1/2-NPT Port. 33. Apply (Actuator Assembly ID Tag #25) to lower case. Use 2 each (Drive Screws #40). 34. Test according to API 6A latest edition. This testing excludes hydrostatic testing of the actuator. 35. After testing is complete thread (Pressure Relief Device #21) into (Top Plate Assembly #7) . 36. Use Teon tape or Teon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate. 37. All assembly and testing must be performed by certied personnel. 38. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will be serialized and documented by certied personnel.
PISTON ACTUATOR EXPLODED VIEW page 20
page 21
ARRAY BONNET ASSEMBLY The bonnet is part of the actuator that connects the actuator to the valve. The following outlines the assembly of the Array Bonnet Assembly. All item numbers correspond to Bill of Material items. CAUTION: It is imperative that when assembling the Bonnet, the assembly area be clean and free of all ying debris.
PROCEDURE 1. Examine the (Packing Retainer #32). Verify that bore threads are clean and in good condition and o-ring grooves are clean and in good condition. 2. Install (O-Ring #33) and (O-Ring #34) to (Packing Retainer #32). 3. Thoroughly lubricate the entire part with assembly lubricant and then set aside. 4. Examine the (Bonnet #38). Verify that bore and threads are clean and in good condition. 5. Thoroughly clean the Bonnet bore and outer diameter threads and lightly lubricate packing box with assembly lubricant. 6. Install the (Bonnet Packing #36), 3 pieces, in the bonnet packing box with the packing o-ring energizer facing down. Push the packing rings down to a positive stop. 7. Pick up the (Packing Retainer #32) and carefully thread the retainer into the Bonnet with clockwise rotation to a positive stop. Tighten retainer securely with a pipe wrench. Note: Remove any metal shavings or bits of residue from wrench operation. 8. Install a (Test Fitting #35) in the tapped hole in the Bonnet ange and tighten tting securely. Use pipe tape or liquid (Teon). 9. Examine the (Bonnet Stem #37). Verify that threads are clean and in good condition, seal surface is clean and free of nicks, dings, burrs or scratches. 10. Lightly lubricate the entire seal surface of the stem with assembly lubricant. 11. Pick up the Bonnet and place it on its side. 12. Pass the Stem through the Bonnet and packing set, from the ange side of the Bonnet until the Stem backseat contacts it’s stop point. Caution: Be careful not to nick I.D. sealing surface of packing by nose of bonnet stem. Note: the design of the Stem/Gate connection will vary depending
on size, working pressure and manufacturer.
page 22
ARRAY BONNET TO GATE VALVE ASSEMBLY The Array Products Bonnet Assembly when installed on an unbalanced valve is the interface between the Actuator and the gate valve. The Bonnet will provide leak free sealing. Before adapting the actuator the bonnet stem should be stroked freely by hand in both directions. When the valve is pressurized in the full closed position the stem will be urged outward because of the valve pressure acting on the bonnet stem diameter. The Array Products bonnet is used as an up and down stop for the valve. This design prevents damage to the valve bonnet stem in the event of accidental over pressuring of the actuator. The bonnet provides positive stroke reliability by use of spacers (provided with the actuator). Once proper stroke has been set, a constant stroke distance will be maintained through the normal service life. All Array bonnet assemblies are shipped ready for installation on the valve. Warning:If you are installing a pre assembled Fail safe bonnet and Actuator assembly to
a gate valve some precautions need to be taken to prevent damage to the assembly. While installing the gate to the bonnet stem the stem must not be back seated. Apply sufcient control pressure to the actuator to unseat the re seal. This will prevent damage to the re seal in the event the stem is rotated during installation of the gate. If the stem must be rotated to align the gate to the gate valve, it can only be rotated in the clockwise direction. If the stem is rotated in the counterclockwise direction it may unscrew from the down-stop. This will affect the drift setting of the valve and could cause damage to the actuator and the valve assembly. The stem will not rotate in the clockwise direction with full actuator control pressure applied. You must only apply enough control pressure to allow access to the gate to stem connection. WARNING:During installation pay special attention to removal of any devices on the
valve such as stem balancing components, internal gate down stop devices and any adjustments to gate travel.
PROCEDURE 1. Push the (Bonnet Stem #37) down out of the (Bonnet #38) until the stem end for gate adaption is exposed. 2. Thread the gate onto the exposed portion of the stem in a closing direction. Position gate as required by valve manufacturer’s installation procedure. 3. Rotate the gate slightly in either direction to align the slot in the stem with the mating hole in the gate lift nut. Drive the pin (supplied by the valve) through the gate pin hole in the stem slot. 4. Install new bonnet seal ring (supplied with the valve) in the valve body and then carefully lower the gate into the valve body, between the seats and allow the bonnet to pass over the valve body stud. 5. Install the valve body nuts on the studs and make up connection as required by valve. 6. The (Bonnet Stem #37) should slide easily upwards by pulling the gate up to the fully closed position with your hands. The (Downstop #18) can be threaded onto the stem for better leverage. Do not use any other device or tool to life the (Bonnet Stem #37) to the fully closed position other than previously mentioned.
ACTUATOR TO BONNET & GATE VALVE ASSEMBLY 1. The bonnet assembly is installed on a reverse acting gate valve. (See bonnet to gate valve assembly) and the drift properly set with the correct amount of shims. (See setting the valve drift section) 2. With Bonnet and valve assembled in the vertical position, thread the (Bonnet Ring #20) onto end of (Bonnet #38). Rotate by hand in a clockwise manner till tight. Lock the thread by installing a bolt into hole completely. Using a dead blow hammer tap bolt head to tighten (Bonnet Ring #20) securely. Tap bolt so bonnet ring rotates in a clockwise direction. 3. Install two (Locking Screws #28) and (Cam Clamps #29) into tapped holes at base of (Bonnet #38). Tighten securely. Note: Make sure at on cam clamp is loading O.D. of bonnet neck. 4. Grease top of spring groove on (Bonnet Ring #20) lightly.
5. Install (Spring #17). Grease top of spring. 6. With (Bonnet Stem #37) fully extended, place (Spring Retainer Plate #16) on top of spring. Place (Downstop #18) on end of (Bonnet Stem #37) and rotate in a clockwise direction. Tighten securely. Note: Spring will rotate while tightening stem nut. This is normal and no cause for alarm. 7. Lift assembled actuator down onto assembled bonnet kit. Leave plugs out of actuator side ports so air can exhaust. The actuator should drop down and stop on bonnet ring shoulder. Align holes in lower housing to tapped holes in bonnet ring. Torque 8 (Housing Bolts #22) to 60–75 ft. lbs. 8. Testing can now begin. Install a solid 1/2 NPT plug in one of the two nipples located on the side of the top diaphragm housing. 9. Consult the particular API section of “Actuators”. The following section applicable to testing is 10.16. 10. After completion of testing, install (Pressure Relief Device #21). Use Teon tape or Teon liquid, tighten securely. Wipe off excess liquid if used. 11. Apply (Actuator Assembly ID Tag #25) using 2 (Drive Screws #26) to (Lower Plate Assembly #24). Location should not interfere with exhaust holes or bolt holes. Contour nameplates to t outer diameter of housing. Eliminate any sharp edges that may cause injury to personnel.
page 23
page 24
SETTING THE GATE VALVE DRIFT 1. Setting the drift can only be accomplished after the bonnet assembly has been installed on the gate valve. All studs and bolts have been torqued with all stem to gate connections completed. 2. With the gate valve in the vertical position, place four (Drift Shims #41) on top of the packing retainer. 3. Thread the (Downstop #18) onto the bonnet stem to a dead stop. 4. Using both hands, push down on the stem nut to bottom out on top of the shims. 5. Check the drift alignment by running the appropriate size drift tool through the bore. If the gate is not aligned with the valve bore, pull up on the stem to the fully closed position and remove the down stop and add or subtract shims as required to properly align the gate with the gate valve bore. (See Illustration) 6. The stroke length is now set permanent.
page 25
GATE GATE
ADD SHIMS
REMOVE SHIMS
FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING 1. Disconnect power source going to actuator pressure inlet. 2. Do not disconnect the pressure relief device 3. If a quick exhaust valve is used, disconnect from actuator and set aside. Caution:The piston or diaphragm in the quick exhaust may not shift totally thereby trapping a small amount of air pressure in top case. This could be injurious to personnel. 4. If electronic proximity switches are installed remove them from top of diaphragm case. Do not injure or mishandle. Set aside. Be aware when removing switch bracket so as to correctly install properly later. Caution:All wire leads must be replaced carefully. 5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear stem protector, fusible lock open cap. Caution:If fusible or mechanical lock open cap is installed on the Actuator, prior to any disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will prevent injury to personnel. After pressurizing Actuator, unscrew fusible or mechanical cap and set aside. 6. Remove all (Attachment Bolts #27), 8 each, from base of Actuator (Lower Plate Assembly #24). Caution:Remove bolts in a star method. If the removal torque becomes harder as you remove the bolts there could be pressure trapped in the piston actuator. Remove pressure before continuing to remove bolting. Lift actuator off of spring cartridge and bonnet and set aside. 7. Remove piston actuator from bonnet kit and set aside. If weight is a problem add a lifting eye (full thread engagement) to top shaft and lift by mechanical means. 8. Using a spanner wrench remove (Downstop #18) by rotating in a counterclockwise direction. 9. Remove (Spring Retainer Plate #16), (Spring #17), and (Drift Shims #41), set aside. 10. Remove (Packing Retainer #32), rotate in a counterclockwise direction, using a pipe wrench. Caution: Be careful not to nick the sealing surface O.D. of the (Bonnet Stem #37) with the removal of the (Packing Retainer #32). Caution: A hissing noise may be evident indicating trapped pressure and well condensate. Be very careful with eye and hand protection. Remove packing retainer, lift off bonnet stem and set aside. Caution:Check for H2S ppm well content. Be prepared to wear proper protection if well content is above safe levels. 11. Remove (Bonnet Packing #36), 3 rings. Use o-ring pick to remove rings out of bore. 12. Clean packing bore and grease generously. Install (Bonnet Packing #36) with o-ring energizer facing down toward gate valve. Do not use pointed or sharp objects to push packing down into bore. Completely set all three pieces of packing. 13. Re-install (Packing Retainer #32). Tighten rmly. 14. Install same number of (Drift Shims #41) onto packing retainer. 15. Install the (Spring #17) onto the (Bonnet Ring #20) at the free length position. 16. Thread the (Downstop #18) and (Spring Retainer Plate #16) onto end of (Bonnet Stem #37). Downstop must stop on shoulder. 17. Lift actuator onto bonnet assembly. The actuator (Lower Plate Assembly #24) will stop on the shoulder of the (Bonnet Ring #20).
page 26
18. Actuator should slide onto bonnet ring shoulder. Excess air inside housing will exhaust through pressure port. (2) Leave open one of the pressure ports on top of Actuator housing. Air must escape through this port to be installed properly. 19. Align holes on (Lower Plate Assembly #24) with tapped holes in (Bonnet Ring #20). Install 8 (Attachment Bolts #27) and torque to 60 to 75 ft. lbs. 20. Reconnect all accessories to actuator. Securely connect all piping and valves to pressure entry port of actuator inlet nipple. Attach all electrical and fusible accessories to top of actuator if applicable.
page 27
SERVICING ARRAY MODEL APP ACTUATORS 1. Prior to servicing the actuator assembly, it is recommended that this manual be read in its entirety. Should the service technician have any questions or feel that a certain procedure cannot be performed safely, contact the factory for assistance. 2. For safety precautions and due to the weight and/or size of some actuator assemblies and the presence of pressurized uids in the actuator and valve, personnel should be wearing the proper safety equipment such as steel toe shoes, hard hats, safety goggles and lifting support belts. 3. When moving an actuator assembly or heavy parts, suitable lifting devices such as hoists should be used. It is recommended that the weights of the equipment being serviced be obtained from the appropriate gate valve manufacturer’s technical bulletins to conrm that any lifting equipment to be used is adequate. Caution: When using lifting eyes make sure they are forged single piece design. Engage thread completely before lifting. 4. DONOT attempt to remove any items from the actuator assembly when it is pressurized. BLEED OFF ALL control pressure and disconnect the supply lines before performing any service functions. Failure to do so could result in equipment damage or personal injury. 5. The work are should be clean and free of contaminents such as dirt, sand and metal shavings etc. 6. All grease or lubricants must be free of any contaminents. Any utensils such as brushes or applicators must also be free of any foreign particles. 7. All tools used should be clean, in good working order and be the proper tool for the operation to be performed. 8. Keep all elastomers and/or replacement parts in the srcinal storage or shipping packaging until installed. 9. Cleaning must be nished prior to installation or inspection of any new or used component. A suitable uid should be used that is compatible with the part being cleaned. Most naptha based solvents are good for heavy de-greasing of metallic parts. A solution of warm soap and water is recommended for all non-metallic pieces or simply wipe with a clean cloth. The use of commercially available aerosol dispensed brake cleaners may be used on metal parts only. Caution:If part is coated, test the vapor build up if using indoors. 10. All new or used parts must be examined after cleaning burrs, dings and nicks prior to using them. 11. Lightly lubricate all seals and sealing surfaced with a suitable grease prior to installing them. 12. When handling any parts that have sealing surfaces, care should be taken not to mar those surfaces. 13. Caution:failure to follow the procedures given in this manual may result in equipment damage, operating problems and/or personal injury.
page 28
TESTING
page 29
1. The new assembled actuator will be tested per API 6A, latest edition. Section 10.16 is applicable. a. Verify that all mechanical lock open devices are removed when proceeding with operational testing and back seat testing. b. Hydrostatic testing of actuator, bonnet and gate valve may employ a mechanical override only. NO LOCK CAPS ARE TO BE USED ON HYDROSTATIC TESTING. c. Remove the pressure relief device from the actuator. After testing is complete the safety relief device will be assembled to the actuator. Use a gauge or solid plug as a replacement. d. In house testing will use hydraulic/nitrogen for functional testing. If problems arise during testing with the actuator, disassemble. Repair and re-assemble. e. All testing must be performed by certied assemblers and testers.
PERIODIC MAINTENANCE The following maintenance schedule is recommended to insure safe and reliable operation of the Array Model APD Actuator.
MAINTENANCE OPERATION
INTERVAL
1.
Cycle actuator under normal operating conditions.
Monthly
2.
Inspect pressure relief device Check for leakage around threads.
Monthly
3.
Inspect Top Shaft
Monthly
4.
Check top shaft packing retainer and retainer ring in top of cylinder
Monthly
5.
Replace All Seals
Every ve (5) years or when leakage occurs
TROUBLESHOOTING TROUBLE
Actuator will not stroke on a Valve Whether or not Valve is Pressurized
Actuator will not attach to Bonnet Assembly (Bonnet Ring)
Actuator will not stroke to full closed or ‘Fail Safe Close’ Position
page 30
PROBABLE CAUSE
REMEDY
Insufcient pressure in control line
Verify pressure availability from source. Consult control pressure information from the sizing chart or matrix.
Valve and/or seats improperly installed
Remove actuator as instructed per this manual. Remove bonnet as per bonnet manufacturer’s operating instructions. Repair and/or replace valve components as per valve manufacturers repair manual.
Gate/Seat Galled
Remove bonnet kit. Inspect gate and seats and replace if necessary.
Debris in shaft or housing
Re-inspect housing and spring
Bonnet stem is not fully extended.
Grasp stem in bonnet and pull to full extension properly back-seating system.
Bad or wrong thread on bonnet stem and down-stop on bonnet/ ring assembly
Check threads on bonnet and pull to full extension properly back-seating system.
Spring cartridge too long because of bonnet engagement to down stop
Check thread engagement on bonnet stem and downstop for burrs, nicks, dings and debris. Check size and thread pattern for proper engagement.
Downstop not fully engaged to bonnet stem
Remove actuator and tighten downstop to bonnet stem.
Gate and seats are improperly installed causing excessive friction
Remove actuator as instructed per this manual. Manually push and/or pull bonnet stem to determine severity of binding. If severe, remove bonnet, gate and seats, clean and inspect gate and seats for wear and abrasion. Replace if necessary.
Excessive seal friction due to loss of lubrication in bonnet/valve
Lubricate in accordance with manufacturer’s maintenance manual
Improper gate to stem engagement
Remove actuator as instructed per this manual. Remove bonnet as per bonnet manufacturer’s instructions and/or drawings, re-assemble. This problem only applies to certain valves.
TROUBLESHOOTING TROUBLE
Actuator housing stops prior to aligning with bonnet ring
Piston Pneumatic Actuator will not stroke to open position. Actuator is in fully closed position
page 31
PROBABLE CAUSE
REMEDY
Bonnet ring threaded down to positive stop
Check for thread engagement between downstop and bonnet stem
Actuator control supply too low (psi)
Check regulator and control pressure gauge
Shut in tubing head pressure too high (psi)
Gauge on top cap illustrates shut in pressure/owing. Change actuator control Actuator will not stroke after psi increase.Contact factory or double actuators.
Piston o-ring leaking
Air will ow through four holes at base of lower housing. Use (snoop) or a soapy substance.
Piston retainer nut o-rings leaking
Remedy same as above
Top Shaft Polypak™ seal leaking
Spray (snoop) on top seal around top shaft. (Will bubble up) Replace seal.
Relief valve or burst disc bad
Air will exhaust, hold hand over to check. (CAUTION!)
Bad quick exhaust valve (piston not shifted)
Remove quick exhaust check piston or diaphragm for movement
Upstream Seat sealing on gate (double blocked)
Valve could be double blocked. Bleed down body pressure if applicable
Gate galled against seat
Remove actuator downstop, spring retainer and spring, negotiate bonnet stem by hand
Packing seized
Remedy same as above
MODEL APP PISTON PNEUMATIC ACTUATOR page 32
ACTUATOR SPECIFICATIONS Maximum Operating Pressure: Test Pressure: API Material Class: API Temperature Rating:
170 psi / (12 Bars) 255 psi / (18 Bars) BB P -20º F to 180º F (-29º C to -82º C)
BONNET SPE CIFICATIONS Bonnets Available for Valve Brands: Size Range Available: Pressure Ranges Available: API Material Classes Available:
Any Manufacturer (with Current Interface Drawing) API 6A 113/16” through 71/16” See Control Pressure Chart AA,BB,CC (non-NACE) DD-0,5 / DD-1,5 / DD-NL EE-0,5 / EE-1,5 / EE-NL FF-0,5 / FF-1,5 / FF-NL HH-NL
API Product Specication Levels Available: API Temperature Ratings Available:
PSL-1, 2 or 3 L through X
LIMITED PRODUCT WARRANTY The following warranty is exclusive and in lieu of all other warranties. Whether express, implied or statutory, including, but not by way of limitation, any warranty of merchantability or tness for any particular purpose.
Array Products warrants to each srcinal buyer of products manufactured by Array that such products are free from defects in material and workmanship under normal use and service for a period of one (1) year from the date of shipment provided that no warranty is made with respect to: Any product which has been repaired or altered in such a way in ARRAY’s judgment, as to affect the product adversely; Any product which has, in ARRAY’s judgment, been subject to negligence, accident or improper storage; Any product which has not been operated or maintained in accordance with normal practice and in conformity with recommendations and public specication of Array.
ARRAY’s obligation under this Warranty is limited to use reasonable efforts to repair, replace or, at it’s option, refunding the purchase price. The cost of labor for installing a repair or replacement product shall be borne by Purchaser. Replacement parts provided under the terms of this Warranty are warranted for the remainder of the warranty period of the products upon which they are installed to the same extent as if such parts were srcinal components thereof. Warranty services provided there under do not assume any liability for damages caused by any delays involving warranty service. For complete specication information, prices and name, address and telephone number of the ARRAY representative nearest you, call or write to us at the address below.
ARRAY HOLDINGS, INC., D.B.A. ARRAY PRODUCTS 15900 Morales Road, Houston, Texas 77032
Phone: 281.977.8500• www.array.com
©2010Array Holdings, Inc. All specications and materials are subject to change without notice.
