USER INSTRUCTIONS. Valtek VL-ES Actuators. Installation Operation Maintenance. Experience In Motion FCD VLENIM /06

Transcription

1 USER INSTRUCTIONS Valtek VL-ES Atuators FCD VLENIM /06 Installation Operation Maintenane Experiene In Motion

2 Contents 1 General Information Using Appliability Terms Conerning Safety Protetive Clothing Qualified Personnel Installation Spare Parts Servie / Repair Storage Produt Variations 5 2 Unpaking 5 3 Valve Installation 5 4 Dissassembly of VL-ES Atuator 6 5 Assembly of the VL-ES Atuator 7 6 Maintenane 10 7 Deommissioning the Spring-Can 11

3 1 General Information 1.1 Using The following instrutions are designed to assist in disassembling, reassembling and troubleshooting Flowserve Valtek valves equipped with VL-ES atuators. Separate installation, operation and maintenane instrutions over additional features (suh as handwheels, limit stops, fail-safe systems, limit swithes or positioners). Produt users and maintenane personnel should thoroughly review this bulletin in onjuntion with any handwheels or other aessory equipment before installing, operating or performing any maintenane on the valve. In most ases, Flowserve valves, atuators and aessories are designed for speifi appliations (e.g. with regard to medium, pressure, temperature). For this reason they should not be used in other appliations without first ontating the manufaturer. 1.2 Appliability The following instrutions are appliable to the maintenane and installation of VL-ES atuators only. This doument should be used in onjuntion with the appropriate Installation, Operation and Maintenane Instrutions speifi to the model of the valve on whih the atuator is installed. 1.3 Terms Conerning Safety The safety terms DANGER, WARNING, CAUTION and NOTE are used in these instrutions to highlight partiular dangers and/or to provide additional information on aspets that may not be readily apparent. b DANGER: indiates that death, severe personal injury and/or substantial property damage will our if proper preautions are not taken. WARNING: indiates that death, severe personal injury and/or substantial property damage an our if proper preautions are not taken. a CAUTION: indiates that minor personal injury and/or property damage an our if proper preautions are not taken. NOTE: indiates and provides additional tehnial information whih may not be obvious, even to qualified personnel. Compliane with other notes, whih may not be partiularly emphasized, with regard to transport, assembly, operation and maintenane and with regard to tehnial doumentation (e.g. in the operating instrutions, produt doumentation or on the produt itself), is essential in order to avoid faults, whih, in and of themselves may diretly or indiretly ause severe personal injury or property damage. 1.4 Protetive Clothing Flowserve produts are often used in problemati appliations (e.g. under extremely high pressures or with dangerous, toxi or orrosive mediums). When performing servie, inspetion or repair operations, always ensure that the valve and atuator are depressurized and that the valve has been leaned and is free from harmful substanes. In suh ases, pay partiular attention to personal protetion (e.g. protetive lothing, gloves, glasses and respirator as required). 1.5 Qualified Personnel Qualified personnel are people who, on aount of their training, experiene, instrution and knowledge of relevant standards, speifiations, aident prevention regulations and operating onditions, have flowserve.om

4 been authorized by those responsible for the safety of the plant to perform the neessary work and who are able to reognize and avoid possible dangers. b DANGER: Before installation, hek the order number, serial number and/or the tag number to ensure that the valve/atuator is orret for the intended appliation. WARNING: Standard industry safety praties must be followed when working on this or any proess ontrol produt. Speifially, personal protetion and lifting devies must be used as warranted. 1.6 Installation Do not insulate extensions that are provided for hot or old servies Pipelines must be orretly aligned to ensure that the valve is not fitted under tension The user must provide fire protetion. 1.7 Spare Parts Use only Flowserve original spare parts. Flowserve annot aept responsibility for any damages that our from using spare parts or fastening materials from other manufatures. If Flowserve produts (espeially sealing materials) have been on store for long periods of time hek these produts for orrosion or deterioration before using them. The end user must provide fire protetion for Flowserve produts. 1.8 Servie / Repair To avoid possible injury to personnel or damage to produts, the safety terms must be stritly adhered to (see Setion 1.3). Modifying this produt, substituting non-fatory parts, or using maintenane proedures other than those outlined in this instrution manual an drastially affet performane, be hazardous to personnel and equipment, and may void existing warranties. Between the atuator and the valve there are moving parts. To avoid injury, Flowserve provides pinh-point-protetion in the form of over plates, espeially where side-mounted positioners are fitted. If these plates are removed for inspetion, servie or repair speial attention is required. After ompleting work the over plates must be refitted. Apart from the operating instrutions and the obligatory aident prevention diretives valid in the ountry of use, all reognized regulations for safety and good engineering praties must be followed. WARNING: Before produts are returned to Flowserve for repair or servie, Flowserve must be provided with an MSDS (Material Safety Data Sheet) and a ertifiate, whih onfirms that the produt has been deontaminated. Flowserve will not aept deliveries if the MSDS and the ertifiate have not been provided (a form an be obtained from Flowserve). Sine the paking box annot be leaned without removing paking, valve paking should be removed and the paking area flushed as part of the leaning Storage In most ases, Flowserve produts are manufatured from stainless steel. Produts not manufatured from stainless steel are provided with an epoxy resin oating. This means that Flowserve produts are well proteted from orrosion. Nevertheless, Flowserve produts must be adequately stored in a lean, dry environment. Plasti aps are fitted to protet the flange faes by preventing the ingress of foreign materials. These aps should not be removed until the valve is atually mounted into the system.

5 1.10 Produt Variations These instrutions annot laim to over all the details of every possible produt variation, nor in partiular an they provide information for every possible example of installation, operation and maintenane. This means that the instrutions normally inlude only the diretions to be followed by qualified personnel using the produt for its defined purpose. If there are any unertainties in this respet, partiularly in the event of missing produt related information, larifiation must be obtained via the appropriate Flowserve sales offie. 2 Unpaking While unpaking the atuator, hek the paking list against the materials reeived. Lists desribing the atuator and aessories are inluded in eah shipping ontainer. 2.1 Position the lifting straps and hoist to avoid damage to the tubing and mounted aessories when lifting the atuator from the shipping ontainer. WARNING: When lifting an atuator with lifting straps through the yoke legs, be aware that the enter of gravity may be above the lifting point. Therefore, support must be given to prevent the atuator from rotating, ausing serious injury to personnel or damage to nearby equipment. 2.2 Contat your shipper immediately in the event of shipping damage. 2.3 Contat your Flowserve representative with any other problems. 3 Valve Installation Prior to installation, make sure adequate overhead learane is provided for the atuator to allow for proper removal from the valve body and for proper maintenane. Refer to Table I. Table I: Dissassembly Clearane Disassembly Clearane Atuator Size Spring in. mm 100 Standard Standard Heavy Duty Standard Heavy Duty Standard Heavy Duty Standard Heavy Duty Make sure the positioner mounting bolts, linkage and stem lamp are fastened seurely. 3.2 Ensure all aessories, brakets and assoiated bolting are fastened seurely. 3.3 Chek rubber bellows for wear. 3.4 Spray soap solution around the base and top of the ylinder, lower atuator stem bushing and the piston stem bushings to hek for air leaks through the O-rings. flowserve.om

6 3.5 Clean any dirt or foreign material from the atuator and piston stems. 3.6 If an air filter is supplied, isolate the air filter, then hek and replae the artridge as neessary. 4 Dissassembly of VL-ES Atuator To disassemble the VL-ES atuator, refer to Figure 1 and 2 and then proeed as follows: 4.1 Shut off the air supply. If the atuator is installed on a Flowserve valve, remove the valve using the appropriate Installation Operation and Maintenane instrutions. WARNING: To avoid serious injury, depressurize the line to atmospheri pressure and drain all fluids before working on the atuator. 4.2 Disonnet all tubing. 4.3 Remove the atuator from the valve body using air in the ylinder to move the plug stem to approximately mid stroke position. Remove the stem lamp and release the air from the ylinder slowly. Remove the yoke bolts. Using lifting rings in the plae of two of the top plate bolts, lift the atuator up off the valve body subassembly. Set the atuator on a workbenh or other sturdy work surfae. WARNING: When lifting an atuator with lifting straps through the yoke legs, be aware that the enter of gravity may be above the lifting point. Therefore, support must be given to prevent the atuator from rotating, ausing serious injury to personnel or damage to nearby equipment. WARNING: Removing the stem lamp without relieving the pressure between the plug stem and the atuator stem an ause the stem lamp to suddenly jump, ausing serious injury to personnel or damage to nearby equipment. 4.4 Remove the over plate bolts, over plate and over plate O-ring. 4.5 For fail open, air to lose (ATC) atuators, apply air the bottom port on the atuator, moving the piston to the top of the ylinder. Remove the piston stem half rings, ollar and thrust washer. 4.6 Remove all but two of the spring-an bolts. Leave in two bolts on opposite sides of the atuator. Remove the two remaining bolts one flat at a time, turning eah in order. Remove the spring-an by lifting it lear of the atuator. b DANGER: The spring-an ontains a pre-tensioned spring. The spring-an must not be disassembled in the field and requires speial equipment and training to servie. Disassembling the spring-an will ause serious injury or death. For instrutions on deommissioning the spring-an, see setion 7.0 below. 4.7 For fail losed, air to open (ATO) atuators, remove the spring guide and thrust washer. 4.8 Remove the four self-loking tie rod nuts by unsrewing them in an alternating pattern. Remove the ylinder end ap. 6 NOTE: When removing the tie rods, spinning the self-loking nuts may ause the entire rod to turn, removing the rods instead of the nuts. In this ase, do not use vise-grip pliers or a similar devie to keep the rod from turning. This will damage the surfae of the tie rod and an ause the rod to fail in servie. Instead allow the rod and nut to ome out as one. One the rod and nut are lear, use a soft grip vise to turn the nut off the tie-rod. 4.9 If the tie-rods did not ome out with the loknuts, remove the tie rods from the yoke using two nuts loked together on the upper threads.

7 4.10 Lift the ylinder off the yoke and piston. If exessive O-ring resistane is felt, use a rubber mallet to gently tap around the ylinder perimeter and gently pry the ylinder off with a flat srewdriver. Remove the piston quad-seal, and two ylinder O-rings. WARNING: To avoid serious personal injury, never use air pressure to remove the piston. The piston may fly out of the ylinder Remove the piston assembly Remove the piston stem, piston and piston O-ring from the atuator stem Remove the O-rings seals from the yoke and end ap The bushings in the yoke and end ap an be pushed out with a press if worn or damaged. 5 Assembly of the VL-ES Atuator The quad seal and all of the O-rings should be replaed and lubriated with a alium omplex grease (Dow 55 or equivalent). Silione O-rings must be lubriated with Magnalube-G lubriant or equivalent. 5.1 Inspet the bushing in the yoke and end ap for damage or exessive wear. Use Table II to determine if the bushings are useable. Exessive wear on these bushings will affet the yle life of the atuator. Replae the bushing if neessary. Table II: Bushing Toleranes Atuator Size Atuator Stem Bushing Piston Stem Bushing Minimum Maximum Minimum Maximum in. mm in. mm in. mm in. mm Replaing the yoke and end ap bushings Remove the old bushings using a press and properly sized pushrods. Take note that the bushings only push out from one side Set the inside bushing by pressing it down to ontat the step in the hole. The smaller bushing is pressed in first. Some bushings may be interhangeable Set the outside bushing to be flush with the surfae. This provides the orret learane for the O-ring to be installed later. 5.3 Inspet the piston stem, atuator stem, piston O-ring and piston for damage or wear. Assemble the piston assembly using Lotite 266 thread loking ompound or equivalent. During assembly, a vie may be used to hold the atuator stem, if desired. Note: When using a vise grip to hold the atuator stem, take are not to damage the stem threads. 5.4 Lubriate and install the four O-rings for the yoke and yoke ap. Lubriate the bushings in the yoke and yoke ap with a light oat of grease. flowserve.om

8 5.5 Insert the piston assembly into the yoke and ylinder. A threaded hole in the piston stem has been provided as a lifting point. Generously lubriate the piston quad seal and install into the piston. The grease should fill the valley between eah of the quad seal lobes. Install the protetive rubber bellows on the atuator stem. 5.6 Lubriate the inside of the ylinder with a light oat of grease. Install the ylinder onto the yoke and piston assembly. Use a soft mallet to gently tap the ylinder into plae. NOTE: Care must be taken as the ylinder and top ap are installed or the O-rings and quad seal an be pinhed. This will ause damage to the seals, whih must then be replaed. Used quad seals will swell somewhat due the effets of the lubriant and new seals should be used whenever the atuator is reassembled. 5.7 Install the tie rods into the yoke using a removable thread-loker (Blue 266 thread loking ompound or equivalent). Using two nuts, jammed together, on the top threads of the tie rod will make installing these rods easier. Remove any nuts used to srew the rods into the yoke. 5.8 Install the end ap onto the piston stem and the ylinder. Take are to line up the air holes on both the yoke and the end ap. WARNING: Damaged tie rods an fail, ausing injury, property damage or death. Damaged tie rods should be replaed. Do not use vie grips or similar devies whih an leave sores and dents in the surfae of the tie rod. Chipped paint should be repainted. WARNING: Tie rods must be fully threaded into the yoke. The tie rod must be flush, or extend slightly beyond the bottom of the yoke. 5.9 Install and tighten the tie rod lok nuts. Then loosen the lok nuts by one turn Using the minimum air supply required, stroke the atuator three times. This provides alignment between the upper and lower stem bushings Tighten the tie rod nuts using Table III to obtain the proper torque values. Table III: Tie Rod Torque Values Cylinder Size ft-lb Nm 100, 150 & & For ATO, fail losed atuators, lubriate the thrust washer on both sides with a alium omplex grease and install both the spring guide and thrust washer Set the spring-an onto the ylinder assembly. Using appropriate anti-seize ompound, install two opposing spring-an bolts and lok washers, tightening half a turn at a time to bring the spring-an down evenly onto the ylinder. Install and torque the remaining spring-an bolts and lok washers, again using appropriate anti-seize ompound For ATC, fail open atuators, stroke the atuator open using the low pressure air. Lubriate the thrust washer with a alium omplex grease on both sides. Install the ollar, thrust washer and half rings. The half rings are slightly bent to keep them loked into plae. They will need to be gently tapped into plae to squeeze them into the groove. Slowly release the air from the ylinder, loking the half rings into plae.

9 5.15 Install the positioner, tubing and other aessories. Use of an air filter is always reommended. Use a soap solution to make sure all air onnetions are leak-free Install the maximum air supply pressure stiker and regulator if required. NOTE: In some ases, air supply must be limited; this will be indiated by a stiker found near the upper air port on the ylinder. WARNING: To avoid personal injury or equipment damage, do not exeed the reommended supply pressure Lower the atuator onto the valve body using lifting rings in plae of two opposing over plate holes and install the yoke bolts finder tight. Replae the lifting lugs with the bolts and lok washers using appropriate anti-seize. If the atuator uses a single piee stem lamp, this must be put over the plug stem before the atuator is installed. WARNING: When lifting an atuator with lifting straps through the yoke legs, be aware that the enter of gravity may be above the lifting point. Therefore, support must be given to prevent the atuator from rotating, ausing serious injury to personnel or damage to nearby equipment Most VL-ES atuators use a split stem lamp. This lamp omes in two piees and has male threads on the atuator and plug stem. One piee stem lamps have female threads in the atuator stem For split stem lamps: Make sure the plug is firmly seated into the seat ring. Using air, stroke the atuator stem down until it is about 1 8" from the plug stem. Install the stem lamp and tighten. Stroke the valve several times to align the atuator and plug stem. With the plug stem off the seat, tighten the yoke bolts to finger tight Loosen the stem lamp to finger tight. Using the appropriate installation instrutions, adjust the plug stem position and tighten the stem lamp For one piee stem lamps: With the atuator lowered onto the valve, the plug stem and atuator stem should be touhing. Before proeeding, verify the stem lamp is on the plug stem. The atuator must be rotated to srew the atuator stem onto the plug stem. Rotate the atuator down on the plug stem engaging the threads between the plug and atuator stem. Use wrenhes on the flats provided on the plug stem and atuator stem to turn the atuator. Continue to turn the atuator on until the yoke ontats the bonnet Lift the stem lamp into plae and tighten to finger tight One the atuator is on the valve, the plug stem engagement into the atuator stem must be adjusted. This adjustment is ritial to shutoff and fail ation Verify that the stem lamp is only finger tight. Verify that the yoke bolts are in plae, but loosened to a ¼ to ½ inh gap Using air on the atuator, lift the plug off the seat and adjust the plug as needed. Stroke the plug down and wath for a gap where the yoke meets the bonnet. Continue to repeat this step until the plug ontats the seat and lifts the atuator, making a gap between the yoke where it ontats the bonnet of about 1 16". 9 flowserve.om

10 NOTE: Rotating the plug while it is in ontat with the seat will ause damage to both the plug and seat ring. Take are not to allow the plug to rotate while threading the atuator onto the plug stem Apply air to the atuator to lift the plug off the seat. Tighten the stem lamp and yoke bolts. Use Table IV to find torque values for the yoke bolts. Stroke fully open to fully losed several times to verify operation. Table IV: Yoke Bolt Torque Values Atuator Size Spud Size Connetion Type Bolt Size Carbon Bolting (ft-lb) Stainless Bolting (ft-lb) Bolted Bonnet Bolted/Half Ring Bolted Bonnet Bolted Bonnet Bolted/Half Ring Bolted Bonnet For ATC, fail open, valves, remove the air from the atuator and allow the valve plug to bakseat on the bonnet. This should put the plug at the top of the stroke. Using feeler gauges hek to make sure that the upper spring button is not ontating the top of the spring-an. If the upper spring button is in ontat with the top of the spring-an, the spring load is not being applied into the plug and will need to be adjusted Install the over plate, over plate O-ring, bolts and lok washers, using anti-seize ompound. 6 Maintenane At least one every six months, hek for proper operation by following the preventative maintenane steps outlined below. These steps should not be performed while the atuator is in servie. If an internal problem is suspeted with the atuator, refer to the Disassembly and Assembly setions (Setions 4 and 5 respetively). WARNING: To avoid serious injury, the following steps should only be performed with the air supply or positioner input disonneted. 6.1 When disonneting air supply, observe atuator for orret fail-safe ation. 6.2 Examine the atuator for damage aused by orrosive fumes and proess drippings. 6.3 Clean the atuator and repaint any areas of severe oxidation. 6.4 If possible, stroke the atuator and hek for smooth, full-stroke operation. WARNING: To avoid serious injury, keep hands, hair and lothing away from all moving parts while operating the atuator. 10

11 7 Deommissioning the Spring-Can b DANGER: The spring-an ontains a pre-tensioned spring. The welds on the spring-an should not be removed until the spring has been determined to be relaxed. Serious injury or death an result from removing the welds while the spring is still ompressed. Spring-ans must be disassembled using speialized equipment. Before the weld seal is broken, the an must be ontained inside of a press. It is reommended that the spring an be returned to Flowserve for deommissioning. Table V: Spare Parts Kits Atuator Size Soft Goods Stem Bushings* * Inludes both atuator and piston stem bushings 11 flowserve.om

12 Figure 1: Air-to-Open Spring Cap O-ring Spring Cap Bolts Spring Cap Upper Spring Button Spring Can Spring Cap Bolts Lower Spring Button Piston Stem Bushing Piston Stem Thrust Washer Thrust Collar Piston Stem O-ring Piston Quad Seal Tie Rod Piston O-ring Cylinder Atuator Stem Bushings Yoke Atuator Stem Atuator Stem O-ring Stem Clamp Rubber Bellows 12 Stroke Plate

13 Figure 2: Air-to-Close Half Rings Spring Cap Bolts Thrust Washer Thrust Collar Spring Cap O-ring Spring Cap Spring Can Upper Spring Button Spring Cap Bolts Piston Stem Bushing Lower Spring Button Piston Stem O-ring Piston O-ring Tie Rod Piston Stem Piston Quad Seal Cylinder Atuator Stem Bushings Yoke Atuator Stem Rubber Bellows Atuator Stem O-ring Stem Clamp Stroke Plate 13 flowserve.om

14 Figure 3: Exploded Drawing Air-to-Close Air-to-Open 14

15 Figure 4: Optional Bevel Gear Operator Installation 15 flowserve.om

16 United States Flowserve Corp. Flow Control Valtek Control Produts 1350 N. Mt. Springs Parkway Springville, UT USA Telephone: Fax: FCD VLENIM Printed in USA. To find your loal Flowserve representative: For more information about Flowserve Corporation, visit or all USA Flowserve Corporation has established industry leadership in the design and manufature of its produts. When properly seleted, this Flowserve produt is designed to perform its intended funtion safely during its useful life. However, the purhaser or user of Flowserve produts should be aware that Flowserve produts might be used in numerous appliations under a wide variety of industrial servie onditions. Although Flowserve an (and often does) provide general guidelines, it annot provide speifi data and warnings for all possible appliations. The purhaser/user must therefore assume the ultimate responsibility for the proper sizing and seletion, installation, operation, and maintenane of Flowserve produts. The purhaser/user should read and understand the Installation Operation Maintenane (IOM) instrutions inluded with the produt, and train its employees and ontrators in the safe use of Flowserve produts in onnetion with the speifi appliation. While the information and speifiations ontained in this literature are believed to be aurate, they are supplied for informative purposes only and should not be onsidered ertified or as a guarantee of satisfatory results by reliane thereon. Nothing ontained herein is to be onstrued as a warranty or guarantee, express or implied, regarding any matter with respet to this produt. Beause Flowserve is ontinually improving and upgrading its produt design, the speifiations, dimensions and information ontained herein are subjet to hange without notie. Should any question arise onerning these provisions, the purhaser/user should ontat Flowserve Corporation at any one of its worldwide operations or offies Flowserve Corporation, Irving, Texas, USA. Flowserve is a registered trademark of Flowserve Corporation. flowserve.om