MODEL APH HYDRAULIC ACTUATOR

Transcription

1 OPERATION & MAINTENANCE MANUAL MODEL APH HYDRAULIC ACTUATOR

2 TABLE OF CONTENTS I. Introduction II. Actuator Operation III. Actuator Technical Specification IV. Actuator Dimensions V. Ordering Information VI. Gate Valve Sizing Matrix VII. Notes VIII. Sizing Charts IX. Sizing Charts X. Sizing Charts XI. Sizing Charts XII. Actuator Valve Sizing Chart Procedure XIII. Actuator/Bonnet Assembly Drawing & Bill of Material XIV. Sub-Assembly Operations Piston Assembly/Assembly Drawing Top Shaft Packing Retainer & Cylinder Assembly/ Assembly Drawing XV. Bonnet Assembly/Assembly Drawing XVI. Bonnet to Gate Valve Assembly/Assembly Drawing XVII. Main Actuator Bonnet and Gate Valve Assembly/ Assembly Drawing XVIII. Setting the Gate Valve Drift/Assembly Drawing Assembly Drawing XIX. Field Removal and Replacement of Actuator Seal & Top Cylinder Seal XX. Field Removal and Replacement of Piston Seal XXI. Field Removal and Replacement of Top Shaft Packing Retainer Seal XXII. Field Removal and Replacement of Bonnet Seal Packing XXIII. Burst Disc Replacement XXIV. Servicing XXVI. Testing and Periodic Maintenance XXV. Troubleshooting XXVI. Product Warranty page 2

3 INTRODUCTION page 3 The Model APH actuator is a piston type, hydraulically-powered gate valve actuator designed to operate a fail-closed or fail-open safety valve. It is ideally suited for wellhead safety valve applications, flow lines, header valves and gathering lines. It can also be used for casing relief valve and storage valve applications. The Model APH actuator is compact, 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 APH 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 APH Hydraulic 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 adequate control pressure to the actuator inlet port. Hydraulic 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 dual set of springs. It will open fail-closed gate valves. Removal of this control pressure allows the bonnet stem forces to return the valve gate to its 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 in the valve. When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft will depend upon whether the valve is fail-closed and how much pressure differential is present across the valve gate. Fail-closed valves will 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 valve gate. The greater the differential, the more rapid the motion for a longer amount of the total valve stroke. The remainder of the actuator motion should be smooth and uniform. Upon removal of control pressure from actuators 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 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. The combination of compression spring assembly will provide approximately 1,750 to 2,000 pounds of force in the closed position of the gate valve.

4 ACTUATOR TECHNICAL SPECIFICATION page 4 1. Applicable Gate Valve Bore 1 13 /16" thru 7 1 /16" 2. Applicable Gate Valve W.P. 2M thru 15M 3. API Classification 6A 4. Trim (API 6A material Class) BB 5. Temperature Classification P -20 to 180 F (-29 C to -82 C) 6. Maximum Operating Pressure 5,000 psi (345 Bars) 7. Maximum Test Pressure 7,500 psi (518 Bars) 8. Pressure Relief (Burst Disc) Setting (Stainless) 5, F ( C) 9. Actuator Volume See chart on page Weight See chart on page Dimensions See chart on page 5

5 ACTUATOR DIMENSIONS page 5 MODEL A B C D E F in mm in mm in mm in mm in mm APH 025 x 020 3" APH 035 x 020 3" APH 035 x 030 3" APH 035 x APH 045 x 020 3" APH 045 x 030 3" APH 045 x 040 3" APH 045 x 050 3" APH 045 x 060 3" APH 065 x 040 3" APH 065 x 050 3" APH 065 x 060 3" APH 065 x 070 3" APH 095 x 070 3" B All Upper Housing Threads are 8 UN-2A C A D F E MODEL SWEPT VOLUME CLOSING TIMES WEIGHT in3 cm3 seconds lbs kgs APH 025 x APH 035 x APH 035 x APH 035 x APH 045 x APH 045 x APH 045 x APH 045 x APH 045 x APH 065 x APH 065 x APH 065 x APH 065 x APH 095 x Note: Swept volumes and closing times represent the maximum actuator stroke.

6 ORDERING INFORMATION The following information should be provided when requesting a quote or issuing a purchase order to Array Products for an APH Actuator. page 6 Actuator Model of Actuator: Size of Actuator: Actuator Control Pressure Availability: Special Requirements: Testing Coating Non-Rising Top Shaft Certification / Specification 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:

7 CONTROL PRESSURE EQUATIONS VALVE WORKING PRESSURE page 7 VALVE 3,000 PSI 5,000 PSI 10,000 PSI 15,000 PSI BORE SIZE APH 025 x 020 APH 035 x psi 3134 psi x wp psi.205 x wp + 59 psi APH 035 x 020 APH 045 x psi 1859 psi.205 x wp + 59 psi.116 x wp psi APH 045 x psi.116 x wp psi APH 025 x 020 APH 025 x 020 APH 035 x 020 APH 035 x psi 2124 psi 2329 psi 3464 psi x wp psi.395 x wp psi.227 x wp + 59 psi.227 x wp + 59 psi APH 045 x 020 APH 045 x psi 2069 psi.130 x wp psi.130 x wp psi APH 025 x 020 APH 025 x 020 APH 035 x 030 APH 035 x psi 2829 psi 2699 psi 4019 psi x wp psi.536 x wp psi.264 x wp + 59 psi.264 x wp + 59 psi APH 035 x 030 APH 035 x 030 APH 045 x 030 APH 045 x psi 1379 psi 1629 psi 2384 psi.264 x wp + 59 psi.264 x wp + 59 psi.151 x wp psi.151 x wp psi APH 035 x 030 APH 035 x 030 APH 045 x 030 APH 045 x psi 1949 psi 3839 psi 3314 psi x wp + 59 psi.378 x wp + 59 psi.378 x wp + 59 psi.213 x wp psi APH 045 x 030 APH 045 x 030 APH 045 x psi 1199 psi 2249 psi.216 x wp psi.216 x wp psi.213 x wp psi APH 035 x 040 APH 035 x 040 APH 045 x 040 APH 045 x psi 2879 psi 3339 psi 4949 psi x wp + 59 psi.564 x wp + 59 psi.322 x wp psi.322 x wp psi APH 045 x 040 APH 045 x 040 APH 065 x 040 APH 065 x psi 1729 psi 1543 psi 2283 psi.322 x wp psi.322 x wp psi.148 x wp + 63 psi.148 x wp + 63 psi APH 045 x 050 APH 045 x 050 APH 045 x 050 APH 065 x psi 2724 psi 5329 psi 3648 psi x wp psi.521 x wp psi.521 x wp psi.239 x wp + 63 psi APH 065 x 050 APH 065 x 050 APH 065 x psi 1258 psi 2453 psi.239 x wp + 63 psi 239 x wp + 63 psi.239 x wp + 63 psi APH 045 x 060 APH 045 x 060 APH 065 x 060 APH 065 x psi 3939 psi 3953 psi 5898 psi x wp psi.770 x wp psi.389 x wp + 63 psi.389 x wp + 63 psi APH 065 x 060 APH 065 x psi 2008 psi.389 x wp + 63 psi.389 x wp + 63 psi APH 065 x 070 APH 065 x 070 APH 065 x psi 2203 psi 4343 psi.428 x wp + 63 psi.428 x wp + 63 psi.428 x wp + 63 psi APH 095 x 070 APH 095 x psi 2008 psi x wp + 43 psi x wp + 43 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)

8 CONTROL PRESSURE EQUATIONS page 8 NOTE: All actuator sizing complies with API 6A (latest edition) force output valve requirements. PSI is required pressure to crack maximum working pressure. Sizing equation includes spring load. PSI number is total of equation and spring load to open gate maximum working pressure. Control pressure equation x valve working pressure + total spring load. When calculating control supply for the APH use this equation. ACTUATOR SELECTION PROCEDURE Determine gate valve specifications such as size, maximum rated working pressure, projected shut-in pressure and maximum flow line pressure. DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY Determine maximum flow line pressure in gate valve. What is the available hydraulic pressure supply at site? Multiply the maximum flow 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.

9 APH SIZING CHART page /16 Nominal Gate Valve APH 025 x 020 Cp =.418 x wp psi APH 035 x 020 Cp =.205 x wp + 59 psi APH 045 x 020 Cp =.116 x wp psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential /16 Nominal Gate Valve APH 025 x 020 Cp =.395 x wp psi APH 035 x 020 Cp =.227 x wp + 59 psi APH 045 x 020 Cp =.130 x wp psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential

10 APH SIZING CHART page /16 Nominal Gate Valve APH 025 x 020 Cp =.536 x wp psi APH 045 x 030 =.151 x wp psi APH 035 x 030 Cp =.264 x wp + 59 psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential /8 3 1 /16 Nominal Gate Valve APH 035 x 030 Cp =.378 x wp + 59 psi APH 045 x 030 Cp =.213 x wp psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential

11 APH SIZING CHART page /16 Nominal Gate Valve APH 035 x 040 Cp =.564 x wp + 59 psi APH 045 x 040 Cp =.322 x wp psi APH 065 x 040 Cp =.148 x wp + 63 psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential /8 Nominal Gate Valve APH 045 x 050 Cp =.521 x wp psi APH 065 x 050 Cp =.239 x wp + 63 psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential

12 APH SIZING CHART page /8 Nominal Gate Valve APH 045 x 060 Cp =.770 x wp psi APH 065 x 060 Cp =.389 x wp + 63 psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential /16 Nominal Gate Valve APH 065 x 070 Cp =.428 x wp + 63 psi APH 095 x 070 Cp=.197 x wp + 43 psi Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential

13 ACTUATOR VALVE SIZING CHART PROCEDURE page To select the proper actuator size and control pressure you must first determine the gate valve bore size and the maximum working pressure of the valve. 2. Now determine the maximum flowing and shut in pressure for production. 3. Determine the available hydraulic control supply pressure at location. 4. Using the appropriate gate valve bore chart, find the y-axis location and draw a vertical line to the top of the chart /16 Nominal Gate Valve APH 045 x 040 Cp =.322 x wp psi Y AXIS Valve Working Pressure (WP) x 1000 psi Required Actuator Control Pressure (psi) to Open Valve at Full Differential 5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point defines the minimum required actuator control pressure to open the gate valve. Example: A valve pressure of 8,400 psi requires an actuator hydraulic control pressure of 2,824 psi to open gate valve (APH 045 x 040). See control pressure equation on pages 7 & 8.

14 PARTS LIST page 14 # DESCRIPTION 1 1 Top Shaft 2 Piston 3 Polypak Seal (AK) 4 Wear Bearing (AK) Top Shaft Retainer Plate 6 Socket Head Cap Screw 7 Top Shaft Packing Retainer 8 Rod Wiper (AK) 9 Wear Bearing (AK) 10 Polypak Seal (AK) 11 Retainer Ring (AK) 12 Cylinder 13 Housing Lock Ring 14 Housing Shear Ring 15 Bolt 16 Spring Adjusting Nut Stem Nut 18 Upper Spring Plate Spring Guide Tube 20 Lower Spring Plate Inner Spring 22 Housing Socket Head Set Screw 24 Bonnet Ring 25 Burst Disc (AK) Caution Tag (NS, AK) 27 Nameplate (NS) Drive Screw (NS) 29 Washers BONNET 30 Bonnet Stem 31 Shim Packing Retainer 33 O-Ring (BK) 34 O-Ring (BK) 35 Polypak Seal (BK) 36 Bonnet 37 Test Fitting Nameplate (NS) 39 Drive Screws (NS) (NS) = Not Shown (AK) = Actuator Redress Kit Items (BK) = Bonnet Redress Kit Items 37 Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves manufactured by companies other than Array Products. In those cases the specific differences are usually limited to the design of the bottom of the bonnet and operating stem.

15 SUB ASSEMBLY OPERATIONS The following procedure outlines the assembly of the actuator. The sub assemblies will be combined into the main assembly. page 15 It is important that the assembly area be clean and free of all dirt particles and any other solid that could impede proper assembly cleanliness. PISTON SUB ASSEMBLY 1. Inspect (Piston #2) one each, for dings, nicks or scratches. Clean thoroughly, inspect sealing surfaces. 2. Lightly cover entire piston with high grade lubricant and set aside. 3. Inspect (Top Shaft Retainer Plate #5) one each, verify that holes and surfaces are clean and free of debris. Lightly grease. 4. Examine (Top Shaft #1) one each, verify finish on seal surface. Lightly grease. 5. The (Socket Head Cap Screw #6) four each, and (Wear Bearing #4) one each, conclude the piston assembly. 6. Check (Polypak Seal #3) for marks and cuts. Inspect energizer o-ring for surface imperfections. Check the sealing edges (O.D./I.D.) carefully by moving fingertips over the surfaces. 7. Place piston on flat clean surface with tapped holes facing upward. Grease sealing diameter and shoulder. Place Polypak over piston groove and push down gently. The Polypak o-ring should be facing upwards. Seat firmly on shoulder. 8. Install top shaft base vertically into counter bore of piston. Seat firmly by hand. Set top shaft retainer plate over and down onto top of piston. Align four holes on the top shaft retainer plate to the four tapped holes in the piston. Apply neverseez lightly to threads. Install all (Socket Head Cap Screws #6). Tighten in clockwise direction. Apply 25 to 30 ft. lbs of torque each. 9. Wipe wear bearing surface clean and install (Wear Bearing #4). The bearing must fit snug with no overlap. The bearing is skive cut and must fit with little or no gap. 10. The piston assembly in now complete. Set aside.

16 TOP SHAFT PACKING RETAINER SUB ASSEMBLY 1. Inspect (Top Shaft Packing Retainer #7) threads and sealing surface. Check for broken or torn threads. Be sure that bore is smooth and bearing groove is clean of debris. page Install (Rod Wiper #8) into top groove of top shaft packing retainer. Inspect rod wiper for tears. Do not grease. 3. Install (Wear Bearing #9) into internal groove of top shaft packing retainer. Make sure bearing is seated into groove properly. No overlap is permitted. The top shaft will not move freely through top shaft packing retainer if bearing is not properly seated. 4. Set top shaft packing retainer aside. CYLINDER SUB ASSEMBLY 1. Inspect all Surfaces on (Cylinder #12) threads for tears and burrs. Inspect bore with hand for ripples, tears, high spots and surface finish. Check top bore for thread tears and surface finish. Check lead in angle at large opening for smooth entry. Inspect two 1 /2 NPT tapped holes for tears or burrs. Clean entire cylinder and grease lightly. 2. Place cylinder in a vertical position with O.D. threads at top. 3. Install (Wear Bearing #9) into bore of (Top Shaft Packing Retainer #7). Clean bore prior to installation. Wear bearing must fold cleanly into bore with no overlap. Skive cut must be clean. 4. Grease top sealing bore generously. Insert (Polypak #10) with o-ring energizer facing downward. Polypak will stop on shoulder. 5. Apply neverseez to threads on (Top Shaft Packing Retainer #7). Insert part into top threaded bore of cylinder. Rotate part in a clockwise direction to a positive stop. Using a wrench, torque the top shaft packing retainer firmly. 6. Install (Retainer Ring #11) into groove located at top of cylinder threaded boss. 7. Grease (Cylinder #12) generously. 8. Place piston sub assembly on a flat planer surface. Lift cylinder sub-assembly up. 9. Align top shaft on piston with bore of cylinder, lower cylinder down and over piston. The piston should enter the cylinder bore smoothly. After the piston has entered bore of cylinder rotate cylinder and piston assembly to the horizontal position. Continue pushing the piston by hand into the bore of the cylinder until top shaft has extended through the top shaft packing retainer. At this point, thread lifting eye into top shaft. Lift the entire assembly and set aside. The weight of the assembly will force the piston to travel further into the cylinder bore until reaching a positive stop.

17 ARRAY BONNET ASSEMBLY page 17 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 flying 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. Thoroughly clean the (Packing Retainer #32), removing all foreign debris from thethreads and o-ring grooves. 3. Thoroughly lubricate the entire part with assembly lubricant and then set aside. 4. Examine the (Bonnet #36). Verify that bore and threads are clean and in good condition. 5. Thoroughly clean the Bonnet bore and O.D. threads and lightly lubricate packing box with assembly lubricant. 6. Install the (Polypak Seal #35) 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 and carefully thread the retainer into the Bonnet with clockwise rotation to a positive stop. Tighten retainer securely with a pipe wrench. Remove any metal shavings or bits of residue from wrench operation. 8. Install a 1 /2" (Test Fitting #37) in the tapped hole in the Bonnet flange and tighten fitting securely. Use pipe tape or liquid (Teflon). 9. Examine the (Bonnet Stem #30). Verify that threads are clean and in good condition, seal surface is clean and free of nicks, dings, burrs and 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. Pick up the Stem and pass the Stem through the Bonnet and packing set, from the flange side of the Bonnet until the Stem backseat contacts its 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.

18 ARRAY BONNET TO GATE VALVE ASSEMBLY page 18 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 pressured 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 though 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 sufficient control pressure to the actuator to unseat the fire seal. This will prevent damage to the fire 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 #30) down out of the (Bonnet #36) until the stem end for gate adaptation is exposed. 2. Thread the gate onto the exposed portion of the stem in a closing direction. Positiongate 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 manufacturer. 6. The (Bonnet Stem #30) should slide easily upwards by pulling the gate up to the fully closed position with your hands. The (Stem Nut #17) can be threaded onto the stem for better leverage. Do not use any other device or tool to lift the (Bonnet Stem #30) to the fully closed position other than previously mentioned.

19 MAIN ASSEMBLY ACTUATOR ASSEMBLY TO BONNET AND GATE VALVE page 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 assembly in the vertical position, install (Stem Nut #17). Rotate in a clockwise direction to a positive stop. Using wrench, tighten firmly. 3. Install two (Socket Head Set Screws #23). Use neverseez sparingly. Tighten both screws securely. Caution: inspect both screw engagement into stem nut. No protrusion of either screw is permitted as this will interfere with assembly ofspring adjusting nut. 4. Place (Housing Lock Ring #13) and housing (Housing Shear Ring #14) down onto flange of bonnet. They should remain loose. They will be used upon addition of (Housing #22). 5. Place (Bonnet Ring #24) onto threaded nose of bonnet. Apply neverseez to I.D. threads on bonnet ring. Rotate the bonnet ring counterclockwise to locate the thread start and then clockwise to a positive stop. Grease top portion of bonnet ring generously. The springs will rotate when being compressed. Tighten bonnet ring securely, lock threads. 6. Place the (Inner Spring #21) down onto face of bonnet ring. 7. Place the (Upper Spring Plate #18) down on top of the inner and outer spring set. Align the ring of the plate to match the O.D. and I.D. of the spring set. 8. Install the (Spring Guide Tube #19) into the bore of the upper spring plate. The tube shoulder will nest inside of the spring plate. 9. Place the (Lower Spring Plate #20) into the bore of the spring guide tube until the lower spring plate shoulder stops on the inner shoulder of the spring tube. 10. Thread the (Spring Adjusting Nut #16) onto the (Stem Nut #17) O.D. threads in a clockwise rotation. An adjustable long wrench will be required. Rotate to a positive stop. The two springs are fully loaded at this point. Note: the springs may rotate when being compressed. This action is normal and presents no cause for alarm. 11. Lift the housing carefully over the assembled bonnet and spring cartridge. The (Housing #22) will stop on the shoulder of the (Bonnet Ring #24) on bonnet end. 12. Insert the (Housing Shear Ring #14) into the groove in the housing. CAUTION: Make sure ring is seated and sprung outward on bonnet end. (Must fit tight in groove). 13. Insert (Housing Lock Ring #13) into groove inside of housing shear ring on the bonnet end. Note: if for any reason, the lock ring does not install easily or is cocked in the groove, remove and reseat shear ring, then reinstall lock ring. 14. Install four (Washers #29) and (Bolts #15) into four tapped holes in bottom of bonnet ring. Apply neverseez lightly to threads. Wrench torque firmly. 15. Using lifting eye installed in top shaft, lift cylinder and piston assembly into bore of (Housing #22). CAUTION: be careful when lowering assembly for proper alignment. The cylinder and piston assembly will stop on (Housing #22) shoulder. Remove lifting eye from top shaft. 16. Insert the (Housing Shear Ring #14) into the groove in the (Housing #22). CAUTION: Make sure ring is seated and

20 page 20 spring outward. (Must fit tight into groove). 17. Insert (Housing Lock Ring #13) into groove inside of (Housing Shear Ring #14). Note: if for any reason the lock ring does not install easily or is cocked in the groove remove and reseat shear ring, then reinstall lock ring. 18. Install four (Washers #29) and (Bolts #15) into four tapped holes in top of (Cylinder #12). Apply neverseez lightly to threads. Using wrench torque firmly. 19. Install a solid 1 /2 NPT plug in one of the tapped holes located at the top of the (Cylinder #12). The solid plug should be sealed with Teflon tape or Teflon liquid sealant. Plug to remain during testing. 20. Apply (Caution Tag #26) to O.D. of cylinder. Must be in close proximity to safety relief device. (Not Shown) 21. Actuator testing can now begin. Consult section of actuator testing.

21 SETTING THE GATE VALVE DRIFT page 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 #31) on top of the packing retainer. 3. Thread the (Stem Nut #17) 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.

22 page 22 GATE GATE ADD SHIMS REMOVE SHIMS

23 FIELD REMOVAL AND REPLACEMENT OF ACTUATOR SEAL This procedure can be performed with the actuator installed on the bonnet and gate valve. The actuator can be mounted in the horizontal or vertical position. The large coil springs and housing does not need to be removed. The gate valve does need to be in the fully closed position with the top shaft fully extended. This fully closed position of the reverse acting gate valve position the bonnet stem in the back seated fire safe mode. page 23 Tools required for field disassembly are adjustable wrench large and small; large and small blade screwdrivers; set of allen wrenches, o-ring extraction tool; safety glasses; hard hat and safety boots. PROCEDURE The following procedures should be followed in all cases of disassembling a production hydraulic actuator. When replacing the actuator seals (2 each) from the cylinder follow these directions carefully. 1. Disconnect power source going to Actuator inlet. Be careful not to spill hydraulic fluid. 2. Do not disconnect the pressure relief device. 3. If a high pressure quick exhaust valve is used, disconnect from Actuator and set aside. 4. If electronic proximity switches are installed remove from top of cylinder. Do not injure or mishandle. Set aside. 5. If other accessories are mounted to the top of the Actuator remove and set aside. These accessories can be clear stem protector, fusible manual override and fusible lock open cap. CAUTION: If a fusible 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 and equipment. After pressurizing actuator unscrew fusible cap and set aside. REPLACE TOP CYLINDER SEAL 6. Remove (Retainer Ring #11) from (Cylinder #12) threaded boss. 7. Using an adjustable wrench rotate (Top Shaft Packing Retainer #7) in a counter-clockwise direction. CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged. CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING.

24 FIELD REMOVAL AND REPLACEMENT OF ACTUATOR PISTON SEAL 1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil. page Do not disconnect the pressure relief device. 3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside. 4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set aside. Be aware when removing switch bracket so as to correctly install properly later. 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 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 cap and set aside. 6. Remove 4 each (Bolts #15) and (Washers #29) from top of APH Actuator. Set aside. 7. Remove (Housing Lock Ring #13) and set aside. 8. Using a thin blade screwdriver, remove (Housing Shear Ring #14) Note: Debris may have hidden milled removal slots on ring. If possible clean surface prior to removal. 9. (Housing Shear Ring #14) should be removed easily. If for any reason the ring is difficult to remove, stop and check pressure attachment to (Cylinder #12) and check for trapped internal pressure. 10. Install 3/4-10UNC-2A lifting eye into (Top Shaft #1) Thread complete. 11. After removal of (Housing Shear Ring #14) lift (Cylinder #12) from Actuator (Housing #22) using lifting eye. Set assembly on flat surface. 12. Clean entire outside surface of (Cylinder #12) assembly. 13. Place (Cylinder #12) assembly on a horizontal position and remove lifting eye from (Top Shaft #1) Hold (Cylinder #12) assembly firmly. Push (Top Shaft #1) and (Piston #2) assembly out of cylinder bore. Be careful not to mishandle piston assembly as hydraulic fluid will be present and slippery. Clean piston assembly. Remove piston (Polypak Seal #10), inspect seal. Report any unusual wear patterns on seal I.D. / O.D. or o-ring energizer (extruded). 14. Replace (Polypak Seal #10) seal. Clean entire piston assembly. Grease generously (Cylinder #12) I.D. and entire (Piston #2) assembly. 15. Stand (Piston #2) assembly in a vertical position. Lift (Cylinder #12) assembly over and down onto piston assembly. Align (Top Shaft #1) and bore of cylinder. Gentlylower cylinder and piston assembly. The piston movement into the cylinder will be smooth. Push piston assembly into bore until (Top Shaft #1) is exposed. Thread 3/4-10 UNC-2A lifting eye into top shaft completely. 16. Lift (Cylinder #12) assembly and lower into actuator (Housing #22). Be sure cylinder shoulders on (Housing #22). 17. Install (Housing Shear Ring #14) and (Housing Lock Ring #13). CAUTION: The shear ring must seat properly into groove. The (Housing Lock Ring #13) must fit into space correctly. If the housing lock ring is cocked or wedged the housing shear ring is not installed properly. In this case, remove housing shear ring, clean groove and reinstall. CAUTION: Both rings must be installed properly. 18. Install four (Bolts #15) and (Washers #29) into top of APH Actuator. Tighten firmly. Use neverseez lightly. 19. Reconnect all accessories to Actuator, and piping and valves to present entry port on Actuator Cylinder.

25 FIELD REMOVAL AND REPLACEMENT OF TOP SHAFT PACKING RETAINER SEAL page 25 This procedure can be performed with the actuator bonnet and gate valve installed on a wellhead or flow-line. The actuator bonnet and valve can be mounted in the horizontal or vertical position. The gate valve does need to be in the fully closed position with the actuator top shaft extended. The fully closed position of the reverse acting gate valve positions the bonnet stem in the back seated fire-safe mode. Tools required for field removal of bonnet seals are adjustable wrenches, large and small; pipe wrench - large; packing extraction tool, safety glasses, hard hat and safety boots. PROCEDURE The following procedure should be followed in all cases of disassembling a production hydraulic actuator. When replacing bonnet packing seals the actuator must be removed from the bonnet assembly. 1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil. 2. Do not disconnect the pressure relief device. 3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside. 4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set aside. Be aware when removing switch bracket so as to correctly install properly later. 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 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 cap and set aside. 6. Remove (Retainer Ring #11) from top to (Top Shaft Packing Retainer #7) in a counter clockwise direction. CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged. CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING! 7. Remove (Polypak #10) with extraction tool. 8. Replace with new (Polypak #10). Inspect sealing I.D. and O.D. with fingertips. Grease generously. Install (Polypak #10) by pushing down into bore of (Cylinder #12). The o-ring energizer will face downward toward gate valve when installed. Push until seal stops on shoulder. 9. Reinstall (Top Shaft Packing Retainer #7) by rotating in a clockwise manner until coming to a dead stop. 10. Install (Retainer Ring #11) into top of (Cylinder #12). CAUTION: Be sure to seat retainer ring into groove. 11. Reconnect all accessories to actuator and piping and valves to pressure entry port on actuator cylinder.

26 FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING 1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil. page Do not disconnect the pressure relief device. 3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside. 4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set aside. Be aware when removing switch bracket so as to correctly install properly later. 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 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 cap and set aside. 1. Using an adjustable wrench remove the four (Bolts #15) and (Washers #29) from the base of the Actuator (Housing #22), set aside. 2. Remove (Housing Lock Ring #13) and (Housing Shear Ring #14), set aside. Leave on Bonnet. 3. Install two 3/4-10UNC-2A forged lifting eyes into side of (Cylinder #12) 4. Thread into two holes in (Cylinder #12). Make up thread completely. 5. With an overhead lifting device connect to the two lifting eyes and lift actuator off of the spring cartridge. Set actuator down on clean, flat surface. Leave the two lifting eyes in place. 6. Using a large adjustable wrench, rotate (Spring Adjusting Nut #16) in counterclockwise direction. You are relaxing the spring load from installed position to the free length position. 7. Remove (Spring Adjusting Nut #16) and set aside. 8. Remove (Upper Spring Plate #18), (Spring Guide Tube #19) and (Lower Spring Plate #20) from spring assembly and set aside. 9. Lift (Inner Spring #21) off (Bonnet Ring #24) and set aside. 10. Remove (Drift Shims #31) 11. Leave (Stem Nut #17) in place. 12. With (Bonnet Stem #30) back seated, rotate (Packing Retainer #32) in a counterclockwise direction. Use a medium to large pipe wrench. CAUTION: Be careful not to nick the sealing surface O.D. of the (Bonnet Stem #30). With the removal of the packing retainer 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 of bonnet stem and set aside. 13. Remove (Polypak Seal #35) four rings. Use pick to pull ring out of bore. Set old packing aside. 14. Grease packing bore generously. Install (Polypak Seal #35) with o-ring energizer facing down. Do not use pointed or sharp objects to push packing down into bore. Set all four pieces of packing completely.

27 15. Reinstall (Packing Retainer #32). Tighten firmly. 16. Install same number of (Drift Shims #31) onto packing retainer. page Check (Stem Nut #17) to insure that is fully threaded onto bonnet stem. Check (Socket Head Cap Screws #6) for threaded engagement. They must be tight 18. Install the (Inner Spring #21) onto the (Bonnet Ring #24) springs are at free length position. 19. Place the (Upper Spring Plate #18) onto top of spring set, align spacing. 20. Insert (Spring Guide Tube #19) into bore of (Upper Spring Plate #18). Must shoulder properly. 21. Place (Lower Spring Plate #20). Down into bore of (Spring Guide Tube #19). 22. Thread (Spring Adjusting Nut #16) onto (Stem Nut #17) in a clockwise manner. Use a large adjustable wrench to load the spring set. Continue rotation until (Stem Nut #17) stops on the (Spring Adjusting Nut #16) shoulder. Note: the springs may rotate. This is normal and presents no cause for alarm. 23. Engage the two lifting eyes with the overhead lifting device. Lift the actuator over and down onto (Bonnet Ring #24). The Actuator should stop correctly on the shoulder of the bonnet ring. 24. At the bottom of the Actuator install the (Housing Shear Ring #14). The ring must seat into the groove and be tight. 25. Install the (Housing Lock Ring #13) into groove space. The ring cannot lock or wedge on the groove. If this occurs remove both rings and clean housing groove and reinstall. 26. Install four (Bolts #15) and (Washers #29). 27. Remove lifting eyes from (Cylinder #12). Reconnect all accessories to actuator. Connect all piping and valves securely to pressure entry port on actuator cylinder.

28 BURST DISC REPLACEMENT The burst assembly incorporates four (4) components. The body, cap, disc and disc seat. The following instructions explain the correct method to replace the burst disc assembly. page 28 PROCEDURE For Field Replacement and Repair of Burst Disc Assembly (disc exhausted) 1. Using a large adjustable wrench or box/open end wrench, engage the hex wrench flats on the burst disc housing. Using a second wrench (adjustable/open box) engage the hex flat on the burst disc cap. (Figure 1) Rotate the cap in a counterclockwise direction until completely disengaged. (Figure 2) Remove disc seat and metallic particles of exhausted disc. Clean inner bore and threads from burst disc housing. Install disc into bore. (Figure 3 & 4) Caution: The convex surface of the disc must be facing outward at the installer. (Figure 5) Carefully inspect the disc prior to installation. Make sure the contact surface of the body is clean for the disc to seal. Install the disc seat on top of the disc center carefully. The disc seat can be installed from either side as it is symmetrical. (Figure 6) Engage hex wrench flats on burst disc cap with an adjustable/open end wrench. Rotate the cap in a clockwise direction. Tighten securely. (Figure 7) PROCEDURE For Field Replacement and Repair of Burst Disc Assembly (disc exhausted) 1. Using a large adjustable wrench or box open end wrench, engage the hex wrench flats on the burst disc housing. Firmly, rotate the housing in a counterclockwise direction. Caution: Do not work over the housing during removal. Remove housing from actuator. Clean all Teflon tape or liquid residue from internal and external threads before replacement. Wrap Teflon tape in opposite direction to normal thread engagement around the threaded end of the housing. Wrap securely. If Teflon liquid is used apply generously. Thread housing in actuator. Rotate in a clockwise direction. The recommended torque for tightening the burst disc cap is 50 to 65 ft./lbs. The burst disc assembly is ready for pressure service. Figure 1 Figure 2

29 page 29 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8

30 SERVICING ARRAY MODEL APH 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. page For safety precautions and due to the weight and/or size of some actuator assemblies and the presence of pressurized fluids 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 and a come-a-long 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 confirm 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. DO NOT 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 area should be clean and free of contaminants such as dirt, sand and metal shavings etc. 6. All grease or lubricants must be free of any contaminants. 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 original storage or shipping packaging until installed. 9. Cleaning must be finished prior to installation or inspection of any new or used component. A suitable fluid should be used that is compatible with the part being cleaned. Most naphtha 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 the part is coated, test the vapor build up if using indoors. 10. All new or used parts must be examined after cleaning for burrs, dings, anomalous marks cut, nicks etc. prior to using them 11. Lightly lubricate all seals and sealing surfaces 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.

31 TESTING 1. The new assembled actuator will be tested per API 6A, latest edition. The following section applicable is page 31 a. Verify the following 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. 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 certified assemblers and testers. PERIODIC MAINTENANCE The following maintenance schedule is recommended to insure safe and reliable operation of the Array Model APH Actuator. MAINTENANCE OPERATION INTERVAL 1. Cycle actuator under normal operating conditions. Monthly 2. Inspect pressure relief device (Burst Disc). Monthly Check for leakage around threads. 3. Inspect Top Shaft Monthly 4. Inspect bolts and washers on top and bottom of actuator. Monthly 5. Check top shaft packing retainer and retainer ring Monthly in top of cylinder

32 TROUBLESHOOTING page 32 TROUBLE PROBABLE CAUSE REMEDY Damaged control line Inspect control line for damage and/or leaking fittings Control Pressure in Actuator Will Not Build Insufficient pressure in control line Faulty pressure gauge Install gauge at pressure source to verify desired available Verify pressure gauge is correctly calibrated Leak around top and/or bottom of actuator Replace and/or inspect seal in accordance with assembly instructions Insufficient pressure in control line Verify pressure availability from source. Consult control pressure information from the information chart per size valve application Actuator Will Not Stroke on a Valve Whether or not Valve is Pressurized Bonnet to bonnet stem binding Valve and/or seats improperly installed Consult appropriate maintenance and operating instructions for bonnet 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 manufacturer s repair manual Debris in valve body and actuator vents Remove actuator as instructed per this manual.remove bonnet as per bonnet manufacturer s operating instructions. Clean debris from valve body Debris in shaft or housing Re-inspect housing and spring Actuator Will Not Attach to Bonnet Assembly Bonnet stem is not fully extended and back seated Bad or wrong thread on bonnet stem and down-stop on bonnet/spring assembly Grasp stem in bonnet and pull to full extension,properly back seating system Check threads on bonnet stem and down-stop plate for burrs, nicks, dings and debris. Check size and thread pattern for proper engagement Spring cartridge too long because of bonnet engagement to down-stop Check thread engagement on bonnet stem and down-stop. Check for positive distance between down-stop and drift spacers on packing retainer