Belajar Shutdown Valve
Belajar Shutdown Valve
Belajar Shutdown Valve
INSTALLATION
AND
MAINTENANCE
MANUAL
CONTENTS
GP RANGE
INSTALLATION AND MAINTENANCE
SECTION
CONTENT
PAGE
Introduction
Installation
Maintenance
Fault Detection
10
11
Appendix
Page 2 of 12
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Issue 04/08
INTRODUCTION
GP RANGE
INSTALLATION AND MAINTENANCE
1.0
Introduction
This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid Systems GP
range actuators. Users are responsible to follow the instructions in this manual as well as any additional documentation that
has been supplied regarding the actuator or accessories supplied by Rotork Fluid Systems. Should further information or
guidance relating to the safe use of GP range actuators be required, it will be provided on request. Users are also responsible to
be familiar with and follow any relevant legislation or statutory provisions regarding health and safety.
It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or
on the equipment are properly trained for the work they are performing and are also aware of their responsibilities relating to
health and safety in the workplace. It is extremely important that precautions are taken to avoid spark or static discharge in any
areas of potentially explosive atmosphere.
All Rotork Fluid Systems actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test
certificates and replacement documentation are available upon request. The latest general information regarding any Rotork
product is available on our website www.rotork.com.
INSTALLATION
2.0
Installation
2.1
Electrical Considerations
2.1.1
Any electrical connections required are the responsibility of the user. Connection documentation is supplied with the actuator.
Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are
compatible with the supplied actuator control components.
2.1.2
Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous
area. Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size. Ensure that threaded
adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In
hazardous areas an appropriately certified threaded blanking plug must be used.
2.1.3
Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit to work. Otherwise, all
power should be isolated and the unit moved to a non-hazardous area for repair or attention.
2.1.4
The actuator and control components must be protected from electrical spikes, surges, and lightning strikes as well as
magnetic or electro-magnetic fields. This is the responsibility of the user.
2.2
2.2.1
Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.
2.2.2
Verify that medium composition (e.g., filtration, hydration) correspond to that for with the actuator was manufactured.
Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.
2.2.3
Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas).
Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to
atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork
Fluid Systems if in doubt as to the suitability of the equipment supplied for your application.
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INSTALLATION
GP RANGE
INSTALLATION AND MAINTENANCE
2.3
2.3.1
The maximum temperature allowable for standard build actuators is 100C (212F).Other maximum temperature build
options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the
nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface
temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere.
2.3.2
Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply gas will affect actuator
temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures.
The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment
per the guidelines set forth in EN 1127-1 par 6.4.2.
2.4
Operating Environment
2.4.1
The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the
safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably
protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular
movement.
2.4.2
If the unit has a nameplate indicating that it is suitable for installation in potentially explosive atmosphere (hazardous area), it
must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the
nameplate.
2.5
Mechanical Considerations
2.5.1
It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain the position of the valve and
orientate the actuator accordingly.
2.5.2
Rotork actuators can be mounted on valves in almost any desired position. It is usual however to align the centerline of the
cylinder to the centerline of the associated pipe work.
Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with
respect to gravity to function properly. Contact Rotork Fluid Systems if in doubt.
2.5.3
Ensure all fasteners are adequately tighten to avoid loosening during the course of operation, taking into account vibration
induced by the dynamics of the pipeline.
2.54
All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure
tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the
dynamics of the pipeline.
2.5.5
When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full
opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first
loosening the fixing nut and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from
the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the fixing
nut.
2.5.6
Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide
with the valve stop positions.
2.5.7
Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required.
2.5.8
Once in position, the actuator should operate the valve with a smooth continuous action. If uneven operation occurs, the
pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by
undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing
intermittent motion. Further fault detection procedures are outlined in Section 6.
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MAINTENANCE
GP RANGE
INSTALLATION AND MAINTENANCE
3.0
Maintenance
3.1
Rotork actuators are designed to work for long periods of time in the most severe conditions. However, a preventative
approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide
an actuator maintenance contract tailored to meet each customers individual requirements.
3.2
Any personnel working with or on the equipment must be properly trained for the work they are performing and be aware of
their responsibilities relating to health and safety in the workplace.
3.3
No inspection or repair should be undertaken unless it conforms to any applicable hazardous area certification requirements.
Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the
certification.
3.4
Before performing maintenance, the actuator should be isolated from remote control signals and the pneumatic/hydraulic
power supply. The system should be then be relieved of any internal pressure prior to disassembly.
3.5
Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release
potentially explosive gas and or dangerous liquids.
3.6
After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined section 3.6.
3.7
Periodic Inspection
3.7.1
Ensure that the actuator correctly operates the valve within the required cycle time. The actuator should be cycled several
times with all the existing controls e.g., remote control, local control and manual override; particularly if the actuator is not
frequently operated.
3.7.2
Verify that the power gas supply pressure value is within the required range.
3.7.3
3.7.4
3.7.5
Remove dust and dirt build-up from all actuator surfaces. They can inhibit cooling thus raising the temperature of the
actuator above the maximum allowable limit.
3.7.6
Inspect actuator paint work for damaged to ensure continued corrosion protection. Touch-up as required to applicable paint
specification.
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GP RANGE
4.1
Grease Specification
Manufacturer:
Mobil
Trade name:
Mobiltemp 78
Colour:
Gray/black
Soap type:
Inorganic
Oil type:
Mineral
295/325 dmm
260C
485 cSt
32 cSt
QTY (kg/lb)
0.3/0.66
130
0.4/0.88
0.5/1.10
270, 271
0.8/1.76
350
1.2/2.64
Note: This is the standard grease specification for Rotork Fluid Systems actuators. If an alternative was specified and/or
supplied, it is noted in job specific documentation, which is available upon request.
4.2
Mobil
Trade name:
DTE 11
Viscosity at 40C:
16.5 cSt
Viscosity at 100C:
4.2 cSt
168
ISO Grade:
16
Pour point:
-42C
0.85 kg/dm3
Equivalent to:
Note: This is the standard hydraulic oil specification for Rotork Fluid Systems actuators. If an alternative was specified
and/or supplied, it is noted in job specific documentation, which is available upon request.
Page 6 of 12
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GP RANGE
5.1
Disassembly
5.1.1
Disconnect pneumatic and electrical supply connections. For spring return actuators, ensure that the actuator is in the failed
position (i.e., at end of the spring stroke).
5.1.2
5.1.3
5.1.4
Remove tie rod nuts (34) from the tie rods (22).
5.1.5
5.1.6
5.1.7
Remove housing cover bolts (16), center body cover (15) and cover gasket (14).
5.1.8
Remove piston retaining nut (35) and separate piston (23), shoulder washer (30), and o-ring (36) from piston rod (20).
5.1.9
Remove o-ring (25) and sliding ring (24) from piston (23).
5.1.10
Remove piston rod (20) by unscrewing it from the guide block (4).
5.1.11
Remove flange retaining bolts (13) and remove head flange (18).
5.1.12
5.1.13
Remove bolts (38) and shaft seal retaining flange (37) from the head flange (18).
5.1.14
5.1.15
5.1.16
5.2
Assembly
5.2.1
5.2.2
5.2.3
Cycle the actuator several times. Movement should be smooth and continuous. If not, refer to Section 6, Fault Detection.
NM
M6
8.5
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
1,250
921
M33
1,400
1,030
M36
1,750
1,290
Page 7 of 12
FT. LBS
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Issue 04/08
FAULT DETECTION
GP RANGE
INSTALLATION AND MAINTENANCE
6.0
Fault Detection
In the unlikely event of a fault developing, the following Fault Location Table is provided to assist the maintenance technician.
This table is designed to cover as wide a range of Rotork Fluid Systems actuators as possible. Reference to equipment not
supplied should be ignored.
SYMPTOM
CAUSE
REMEDY
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GP RANGE
INSTALLATION AND MAINTENANCE
48
49
46
44
47
45
42
43
2
41
MATERIAL
17
QTY
Centre body
Guide Bar
Safety Valve
Brass/Stainless Steel
Guide Block
Carbon Steel
Yoke
O-ring
NBR
Upper Bushing
Bronze
Lower Bushing
Bronze
10
Sliding Block
Bronze
11
Bar Pin
Alloy Steel
12
Retaining Ring
Spring Steel
13
Carbon Steel
14
Cover Gasket
Vaporflex/SA
15
Cover
Carbon Steel
16
Carbon Steel
17
Flange Gasket
Vaporflex/SA
ITEM
DESCRIPTION
MATERIAL
18
Head Flange
19
16
39
23
30
36
7 8
15
22
26
4
14
51
19
20
13
ITEM
18
51
50
27
31
21
24
25
33
32
34
40
26
35
28
38
29
Centre body cross-section
10
7 9
13
37
12
11
17
53
55
52
54
57
56
Typical fabricated carbon steel centre body and yoke illustrated.
Some models have a cast, ductile iron centre body and yoke.
MATERIAL
41
Head Flange
Carbon Steel
42
Driving Flange
Carbon Steel
43
Connecting Rod
Bottom Flange
Carbon Steel
44
Bushing
Steel/Bronze/PTFE
22
Tie Rod
Alloy Steel
45
Spring Canister
Carbon Steel
23
Piston
Carbon Steel
46
Spring
Spring Steel
24
Sliding Ring
PTFE/Graphite
47
Stop Bolt
Carbon Steel
25
O-ring
NBR
48
Bottom Flange
Carbon Steel
26
O-ring
NBR
49
Protection Plug
Carbon Steel
27
Shaft Bushing
Steel/Bronze/PTFE
50
O-ring
NBR
28
Seal Washer
Carbon Steel/NBR
51
Shaft Bushing
Steel/Bronze/PTFE
29
Seal Washer
NBR/PTFE/Graphite
30
Shoulder Washer
Alloy Steel
31
Carbon Steel
32
Stop Bolt
Alloy Steel
ITEM
DESCRIPTION
MATERIAL
33
Carbon Steel
52
Flange
Carbon Steel
34
Carbon Steel
53
Flange Nut
Carbon Steel
35
Carbon Steel
54
Seal Washer
Carbon Steel/NBR
36
O-ring
NBR
55
Stop Bolt
Alloy Steel
37
Stainless Steel
56
Carbon Steel
38
57
Carbon Steel
39
Bushing
Carbon Steel
40
O-ring
NBR
QTY
ITEM
Carbon Steel
Cylinder Tube
20
Piston Rod
21
QTY
CLOSURE ASSEMBLY
QTY
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GP RANGE
Overview
1.3
All RFS G Range actuators (ie., GP, GH, GO and HPG) incorporate adjustable stops
to limit the degree of travel in both directions. Steps are outlined below for
adjustment of the three stop configurations: pneumatic/hydraulic cylinder, spring
cartridge and, jackscrew.
Pneumatic/Hydraulic
Cylinder (See figure 1)
1.2
Spring Canister
(See figure 2)
SPRING STOP
SPRING STOP CAP
Jackscrew
(See figure 3)
figure 2
STOP SCREW
SEALING WASHER
STOP NUT
STOP SCREW
SEALING WASHER
SEALING WASHER
STOP NUT
SEALING WASHER
STOP BOLT COVER
figure 1
figure 3
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GP RANGE
1.1
1.2
1.1.1
1.1.2
Loosen the four screws (1) and remove the cover (2).
Setting the CLOSE limit switch.
1.2.1
Loosen the four screws (1) and remove the cover (2).
1.2.2
1.2.2.3 Loosen the setscrew (5) and rotate the cam (4) until
it is on the same axis as the switch and re-tighten the
setscrews.
1.2.3
Replace the cover (2) and tighten the four screws (1).
ITEM
Replace the cover (2) and tighten the four screws (1).
DESCRIPTION
Screw
Cover
Microswitch
Cam
Dowel
Page 11 of 12
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Corporate Headquarters
Rotork plc
tel
+44 (0)1225 733200
fax
+44 (0)1225 333467
email [email protected]
www.rotork.com
PUB011-004-00
Issue 04/08
All Rotork Fluid Systems actuators are manufactured under a third party accredited ISO 9001
quality assurance programme. As we are continually developing our products, their design is
subject to change without notice.
The name Rotork is a registered trademark. Rotork recognises all registered trademarks.
Published and produced in the UK by Rotork Fluid Systems. ROWMH1112