A Zy-Tech Global Industries Product

Transcription

1 A Zy-Tech Global Industries Product

2 Worm & evel Gear Operators Another quality product from Zy-Tech Global Industries, Inc. Zy-Gear gear operators are designed for long lasting dependable service in oil & gas and industrial actuation applications. For years project managers and engineers have specified and relied upon Zy-Gear and other quality Zy-Tech flow control products for petroleum refining, chemical processing, power generating, pulp and paper, water treatment and other processing facilities located throughout the world. The Zy-Gear product line offers a worm or bevel gear model for applications where dependable, accurate actuation is required. The Zy-Gear product offering has been computer designed, manufactured and tested to provide smooth, dependable gear operation for many years. All Zy-Gear gear operators conform to all applicable recognized standards and can be custom designed to meet your project requirements. Specify Zy-Gear gear operators for all your actuation applications and you ll experience first hand what Zy-Tech dependability really means. Visit our website to learn more about Zy-Gear and Zy-Tech Global Industries other flow control products. Contents 3 Zy-Gear Product Range Quick Reference Guide 4 Worm Gear Standard Features 5-9 Worm Gear Engineering Data 10 evel Gear Standard Features evel Gear Engineering Data 14 Specifying Zy-Gear Figure Numbers 14 Zy-Gear Technical Formulas 15 Zy-Gear Installation And Maintenance Zy-Gear is available in worm gear driven models for all your 90 degree turn requirements and bevel gear driven models for multi-turn applications. All Zy-Gear gear operators can easily be fitted for motorized operation.

3 Zy-Gear Product Range Quick Reference Guide Worm Gear Operator Range and Specifications Gear Maximum Travel at Gear Number Mechanical Maximum Mount. Patt. Minimum Maximum Approx. Code Output oth Ends Ratio of Turns Advantage Round ore Straddle Mounting Mounting Wt. w/o Torque to Close and Keyway Centerline Pattern Pattern Handwheel MSS-SP 101 (Pg. #) (ft. lb.) (Degree) (+/-10%) (in.) (in.) (in.) (in.) (lb.) WG / -5 50: Ø 2.13 F14, (4) (Pg. 4) 1 /2 x 3 /8 key 5 /8-11 UNC ON 5.50.C. WG / -5 72: Ø 2.50 FA16, (4) (Pg. 5) 5 /8 x 7 /16 key 3 /4-10 UNC ON 6.50.C. WG / -5 68: Ø 3.43 FA19, (8) (Pg. 6) 7 /8 x 5 /8 key 5 /8-11 UNC ON 7.50.C. WG / : Ø 4.31 FA25, (8) (Pg. 7) 1 x 3 /4 key 5 /8-11 UNC ON C. WG408 32, / : Ø 6.25 FA35, (8) (Pg. 8) 1 /2 x 1 key 1-8 UNC ON C. evel Gear Operator Range and Specifications Gear Maximum Gear Mechanical Maximum Minimum Traditional Minimum Maximum Approx. Code Output Ratio Advantage Stem Dia. Stem Dia. Mount. Patt. Mounting Mounting Wt. w/o Torque w/stem w/o Stem (as shown) Pattern Pattern Handwheel Protector Protector (Pg. #) (ft. lb.) (+/-10%) (in.) (in.) (in.) (in.) (in.) (lb.) G : Ø 2.63 Ø 2.63 (4) 1 /2-13UNC (Pg. 10) on 7.63.C. on Centerline G : Ø Ø (8) 1 /2-13UNC (Pg. 11) on 7.63.C. on Centerline G : Ø 3.95 Ø 4.3 (8) 1 /2-13UNC (Pg. 12) on 7.63.C. on Centerline 3 (8)1-8 UNC on C. Straddle Centerline Handwheel Diameters and Extensions (in.) (Extension measured from stem centerline to outer rim of wheel) Gear Dia. Ext. Dia. Ext. Dia. Ext. Gear Dia. Dia. Dia. WG G WG G WG G WG WG

4 Standard Features of the Zy-Gear Worm Gear Driven Gear Operator Engineered for performance, Zy-Gear worm gear operators incorporates precision design and rugged dependability. Zy-Gear worm gear driven gear operators are designed for valves requiring 90 degree rotation. Zy-Gears are ready to ship from eight computer-linked regional warehouses. High strength cast iron enclosure Feel and sight indicators Four Pre-tapped holes for limit switch mounting bracket Grease fitting Locking device included All Zy-Gear gear operators can easily be converted for motorized applications Precision spur module Highly efficient worm module High strength carbon steel handwheel included Standard Features Permanently sealed and lubricated bearings. Totally enclosed for buried service, seawater submersion, high temperature, low temperature, numerous chemical plant conditions and full weather resistance. Strong cast iron enclosure ensures high torque capability. External mechanical stops allow ± 5 degrees travel and precision setting of the valves closure. Worm gear dual position mounting capability for reversal of rotation direction. Comprehensive product line for torque capability. Tamper proof stop and portion adjustment design. Machine-generated self-lock gearing assures minimum backlash and smooth operation. Sturdy materials, proven design and quality manufacturing ensure trouble-free life. Thrust bearings provide quality operation. Industry interchangeable pre-drilled mounting pattern per MSS SP-101 or ISO square operating nut allows for removal of handwheel and operation by a reach rod. Easily adaptable to motorized services. Passed proof test at 2.5 times maximum output torque. 4

5 Zy-Gear WG008 Worm Gear Operator Parts And Materials Item Part Name Material Cover Carbon Steel 2 O-Ring Nitrile 3 Lock Screw Carbon Steel 4 Stop Screw Carbon Steel 6 Hex olt Carbon Steel 7 End Cap Carbon Steel 8 earing PTFE and Carbon Steel 9 ushing Carbon Steel 10 Worm AISI Grease Fitting rass 12 Pin Carbon Steel 13 Input Shaft AISI O-Ring Nitrile 15 Lock racket Carbon Steel 17 Key Carbon Steel 18 Lock Plate Carbon Steel 20 Square Nut Carbon Steel 21 Handwheel Carbon Steel 22 O-Ring Nitrile 23 O-Ring Nitrile 24 Indicator Plate Cast Iron 26 Cover Cast Iron 27 Gasket Rubber 28 Worm Gear Ductile Iron 29 Housing Cast Iron SECTION Ø F A Tapped Holes 4 x 1/4" UNC olt Circle 4.02" J G D Handwheel Extension I Ø L Ø H K Ø C E SECTION Dimensional Data (in.) Model Wt. (lb.)* A C D E F G H I J K L WG *Approximate weight without handwheel. 5

6 Zy-Gear WG108 Worm Gear Operator Parts And Materials Item Part Name Material 1 Cover Carbon Steel 2 O-Ring Nitrile 3 Lock Screw Carbon Steel 4 Stop Screw Carbon Steel 6 Hex olt Carbon Steel 7 End Cap Carbon Steel 8 earing PTFE and Carbon Steel 9 Thrust earing Commercial 10 Worm AISI Grease Fitting rass 12 Pin Carbon Steel 13 Input Shaft AISI O-Ring Nitrile 15 Lock racket Carbon Steel 17 Key Carbon Steel 18 Lock Plate Carbon Steel 20 Square Nut Carbon Steel 21 Handwheel Carbon Steel 22 O-Ring Nitrile 23 O-Ring Nitrile 24 Indicator Plate Cast Iron 26 Cover Cast Iron 27 Gasket Rubber 28 Worm Gear Ductile Iron 29 Housing Cast Iron 31 ushing Carbon Steel SECTION Ø F A Tapped Holes 4 x 1/4" UNC olt Circle 4.48" G D Handwheel Extension J I Dimensional Data (in.) Ø C E Ø L Ø H SECTION Model Wt. (lb.)* A C D E F G H I J K L WG K *Approximate weight without handwheel. 6

7 Zy-Gear WG208 Worm Gear Operator Parts And Materials Item Part Name Material 1 Cover Carbon Steel 2 O-Ring Nitrile 3 Lock Screw Carbon Steel 4 Stop Screw Carbon Steel 6 Hex olt Carbon Steel 7 End Cap Carbon Steel 8 earing PTFE and Carbon Steel 9 Thrust earing Commercial 10 Worm AISI Grease Fitting rass 12 Pin Carbon Steel 13 Input Shaft AISI O-Ring Nitrile 15 Lock racket Carbon Steel 17 Key Carbon Steel 18 Lock Plate Carbon Steel 20 Square Nut Carbon Steel 21 Handwheel Carbon Steel 22 O-Ring Nitrile 23 O-Ring Nitrile 24 Indicator Plate Cast Iron 26 Cover Cast Iron 27 Gasket Rubber 28 Worm Gear Ductile Iron 29 Housing Cast Iron SECTION Ø F A Tapped Holes 4 x 3/8" UNC olt Circle 6.50" G D Handwheel Extension I J Dimensional Data (in.) Ø C E Ø L Ø H SECTION Model Wt. (lb.)* A C D E F G H I J K L WG K *Approximate weight without handwheel. 7

8 Zy-Gear WG308 Worm Gear Operator Parts And Materials Item Part Name Material Cover Carbon Steel 2 O-Ring Nitrile 3 Lock Screw Carbon Steel 4 Stop Screw Carbon Steel 6 Hex olt Carbon Steel 7 End Cap Carbon Steel 8 earing PTFE and Carbon Steel 9 Thrust earing Commercial 10 Worm AISI Grease Fitting rass 15 Lock racket Carbon Steel 17 Key Carbon Steel 18 Lock Plate Carbon Steel 20 Square Nut Carbon Steel 21 Handwheel Carbon Steel 22 O-Ring Nitrile 23 Lip Seal Nitrile 24 Indicator Plate Cast Iron 26 Cover Cast Iron 27 Gasket Rubber 28 Worm Gear Ductile Iron 29 Housing Cast Iron 31 ushing Carbon Steel 32 Housing (Spur) Cast Iron 33 Cover (Spur) Cast Iron 33A Gasket Rubber 37 earing Dubase Alloy 38 O-Ring Nitrile 39 Input Shaft AISI Spur Gear Carbon Steel SECTION A SECTION AA Tapped Holes 4 x 1/2" UNC olt Circle 7.48" A F D Handwheel Extension G JJ J Ø C E SECTION Dimensional Data (in.) Model Wt.(lb.)* A AA C D E F G H I J JJ K L WG *Approximate weight without handwheel. 8 I Ø L Ø H K

9 Zy-Gear WG408 Worm Gear Operator Parts And Materials Item Part Name Material 1 Cover Carbon Steel 2 O-Ring Nitrile 3 Lock Screw Carbon Steel 4 Stop Screw Carbon Steel 6 Hex olt Carbon Steel 7 End Cap Carbon Steel 8 earing PTFE and Carbon Steel 9 Thrust earing Commercial 10 Worm AISI Grease Fitting rass 15 Lock racket Carbon Steel 17 Key Carbon Steel 18 Lock Plate Carbon Steel 20 Square Nut Carbon Steel 21 Handwheel Carbon Steel 22 O-Ring Nitrile 23 Lip Seal Nitrile 24 Indicator Plate Cast Iron 26 Cover Cast Iron 27 Gasket Rubber 28 Worm Gear Ductile Iron 29 Housing Ductile Iron 32 Housing (Spur) Cast Iron 33 Cover (Spur) Cast Iron 33A Gasket Rubber 37 earing Dubase Alloy 38 O-Ring Nitrile 39 Input Shaft AISI Spur Gear Carbon Steel 41 Dowel Pin Carbon Steel 42 Spur Shaft Carbon Steel 43 Spur Gear Carbon Steel 44 earing Commercial A SECTION A SECTION - AA AA J K Ø L Ø H Dimensional Data (in.) Section I JJ Tapped Holes 4 x 3/4" UNC olt Circle 11.02" G Ø C D Handwheel Extension Model Wt.(lb.)* A AA C D E F G H I J JJ K L WG NA E *Approximate weight without handwheel. 9

10 Standard Features of the Zy-Gear evel Gear Driven Gear Operator Zy-gear bevel gear operators actuate your multi-turn valves. Zy-gear bevel gears are constructed with all the materials, design, technology and engineering you expect to find in a quality gear. They are ready to ship from eight computer-linked regional warehouses. All Zy-Gear gear operators can easily be converted for motorized applications Standard NPT stem protector thread High strength cast iron enclosure High strength carbon steel handwheel included Standard Features O-ring sealed and lubricated for life. Totally enclosed for buried service, seawater submersion, high temperature, low temperature, numerous chemical plant conditions and full weather resistance. High strength cast iron enclosure ensures high torque capability. Comprehensive product line for torque capability. Machine-generated gearing assures minimum backlash and smooth operation. Sturdy materials, proven design and quality manufacturing ensure trouble-free life. Industry interchangeable pre-drilled mounting pattern per MSS SP-102 is available upon request. Adaptable to motorized services. evel pinion and bevel gear supported by anti-friction ball bearings. Stem protector is available in standard NPT pipe sizes. 10

11 Zy-Gear G107 evel Gear Operator Parts And Materials Item Part Name Material 1 Hex olt Carbon Steel 2 Washer Carbon Steel 3 Handwheel Carbon Steel 4 Key Carbon Steel 5 Snap Ring Spring Steel 6 Input Shaft AISI Hex Nut Carbon Steel 8 O-Ring Nitrile 9 Cap Carbon Steel 10 Gasket Rubber 11 all earing Commercial 12 Set Screw Carbon Steel 13 Pinion AISI Grease Fitting rass 15 Housing Cast Iron 16 O-Ring Nitrile 17 Drive Sleeve Ductile Iron 18 Cap Screw Carbon Steel 19 evel Gear AISI alls Hardened Steel 21 O-Ring Nitrile 22 Cap Screw Carbon Steel 23 Snap Ring Spring Steel 24 ase Carbon Steel 25 Key Carbon Steel 26 O-Ring Nitrile SECTION I Ø A Ø C Ø D J Tapped Holes 4 x 1/2"-13 UNC olt Circle 7.63" On Centerline Dimensional Data (in.) Model Wt. (lb.)* A C D (NPT) E F G H I J K G *Approximate weight without handwheel. K Section Driving Lugs Ø G Ø H 45 TYPICAL E F 11

12 Zy-Gear G207 evel Gear Operator Parts And Materials Item Part Name Material 1 Hex olt Carbon Steel 2 Washer Carbon Steel 3 Handwheel Carbon Steel 4 Key Carbon Steel 5 Snap Ring Spring Steel 6 Input Shaft AISI Hex Nut Carbon Steel 8 O-Ring Nitrile 9 Cap Carbon Steel 10 Gasket Rubber 12 all earing Commercial 13 Pinion AISI Grease Fitting rass 15 Housing Cast Iron 16 O-Ring Nitrile 17 Drive Sleeve Ductile Iron 18 Cap Screw Carbon Steel 19 evel Gear AISI alls Hardened Steel 21 O-Ring Nitrile 22 Cap Screw Carbon Steel 23 Snap Ring Spring Steel 24 ase Carbon Steel 25 Key Carbon Steel 26 O-Ring Nitrile 27 Snap Ring Steel SECTION Ø D I Ø A E J K Ø C Section Ø G Ø H F Tapped Holes 8 x 1/2"-13 UNC olt Circle 7.63" On Centerline Driving Lugs 45 TYPICAL Dimensional Data (in.) Model Wt. (lb.)* A C D (NPT) E F G H I J K G *Approximate weight without handwheel. 12

13 Zy-Gear G307 evel Gear Operator Parts And Materials Item Part Name Material 1 Hex olt Carbon Steel 2 Washer Carbon Steel 3 Handwheel Carbon Steel 4 Key Carbon Steel 5 Snap Ring Spring Steel 6 Input Shaft AISI Hex Nut Carbon Steel 8 O-Ring Nitrile 9 Cap Carbon Steel 10 Gasket Rubber 11 all earing Commercial 13 Pinion AISI Grease Fitting rass 15 Housing Cast Iron 16 O-Ring Nitrile 17 Drive Sleeve Ductile Iron 18 Cap Screw Carbon Steel 19 evel Gear AISI alls Hardened Steel 21 O-Ring Nitrile 22 Cap Screw Carbon Steel 23 Snap Ring Spring Steel 24 ase Carbon Steel 25 Key Carbon Steel 26 O-Ring Nitrile 27 Snap Ring Steel 28 Cap Screw Carbon Steel SECTION I Ø A Ø D E J K Ø C SECTION Ø G Ø H F Tapped Holes 8 x 1"-8 UNC olt Circle 14.00" Straddle Centerline Dimensional Data (in.) Model Wt. (lb.)* A C D (NPT) E F G H I J K G *Approximate weight without handwheel. Tapped Holes 8 x 1/2"-13 UNC olt Circle 7.63" On Centerline Driving Lugs 45 TYPICAL 13

14 Specifying Zy-Gear Worm Gear When ordering worm gears pre-bored and keyed from the factory, the following information must be provided. 1. Maximum torque required 2. Gear type: WG008, 108, 208, 308 or ore and keyway size with tolerances. Specify key shape, square or rectangle in width x width. 4. Location of keyway, A,, C or D (see diagram) 5. Mounting pattern in ISO 5211 or MSS SP101 F numbers or special patterns, metric or inch thread holes 6. Handwheel sizes, 18", 24" or 30" diameter C D A TOP VIEW Close Clockwise Zy-Gear Technical Formulas asic Formulas Mechanical Advantage (MA) = Output torque/input torque Overall mechanical efficiency = MA of spur gear x MA of worm gear Input torque =Output torque/ma Output torque = Input torque x MA Efficiency %= [Output torque x 100]/[Input torque x Gear ratio] Overall Efficiency % = [Spur efficiency x worm efficiency] /100 Ratio = Number of turns of input/number of turns of output Overall ratio = Spur gear ratio x Worm gear ratio Number of turns to close = Gear ratio/4 Closing time (min.) = Number of turn to close/input speed (RPM) Closing time (sec.) = Number of turns to close x 60/Input speed (RPM) Input speed (RPM) = Number of turns to close/closing time (min.) Number of turns to close = Input speed (RPM) x Closing time (min.) Torque = Force x Radius Input torque = [Handwheel rim effort x Handwheel diameter] /2 Handwheel rim effort = [Input torque x 2] /Handwheel diameter Handwheel diameter = [Input torque x 2]/Handwheel rim effort Conversion Factor for Force Multiply y To Obtain Pound - Force Newton (N) Newton (N) Pound- Force Newton (N) Kilogram - Force Kilogram - Force Newton (N) Conversion Factor for Torque Multiply y To Obtain Pound - Foot Newton - meter (Nm) Newton - meter (Nm) Pound - Foot Newton - meter (Nm) Kilogram - meter Kilogram - meter Newton - meter (Nm) NOTE: Units must be consistent within the formula. 14

15 Zy-Gear Installation & Maintenance Worm Gear Operator Installation, Adjustment and Maintenance Installation Ensure that gear operator and the valve are both in corresponding positions, fully open or fully closed. If the gear position does not match the valve position, rotate the handwheel until the gear and valve are in the same position. Check to ensure the keyway on valve stem and worm gear are aligned. Install mounting studs into bottom of the worm gear. Align the gear bore with the valve stem and lower the gear to the mounting flange or plate. Fasten the nuts. Adjustment Refer to gear diagram of each model from page 5 to 9 for gear parts. Locate the open side* of the stop screw cover bolt. Remove the cover bolt and o-ring assembly, item 1 and 2, and loosen the lock screw, item 3, and the stop screw, item 4, with an Allen wrench**. Lock screw has a through hex hole with the same size as the socket hole on the stop screw. Allen wrench may go through the socket hole of the lock screw and reach the hole of stop screw. Turn the handwheel to get the true open position of the ball, disc or plug, etc. Turn the stop screw clockwise until it comes into contact with the worm gear. ack up the wrench and make sure the wrench is not engaged with the stop screw. Turn the lock screw clockwise until it contacts the stop screw. Re-install the cover bolt with the o-ring. Turn handwheel to the true closed position; repeat the above steps on the closed side stop screw adjustment. The true closed position of the valve may require setting during the time of the seat leak test. Adjustment Notes *Open side of the stop screw is located at the far side from the handwheel on WG 008, 108, 208 and 408. It is located at the near side from the handwheel on WG 308. In general, if the handwheel is at the right side of the gear at top view, the open stop screw is at the far side. If the handwheel is at the left side of the gear at top view, the open stop screw is at the near side from the handwheel. **Allen wrench sizes needed: WG 008 and WG 108: M12, WG 208: M16, WG 308, WG 408: M24 Maintenance Zy-Gear gears are permanently lubricated for safe operation for the life of the gears and do not require periodic maintenance. evel Gear Operator Installation & Maintenance Installation Inspect the gear to verify it s the right gear specified on the name plate. Ensure that the valve torque is within the gear rating. Support valve in the upright position (Fig. 1). Remove handwheel from the valve (Fig. 2). Place adapter plate* on top of the valve yoke (Fig. 3). Align bolt holes of the adapter plate with respect to the valve bore making sure that gear input shaft will be in desired position after mounting. Align center of the adapter plate with stem center line. Tack-weld plate to valve yoke. Check to verify the alignment, then complete with a full circumferential weld. Set the driver* on the yoke sleeve where the handwheel was set (Fig. 4). Set the gear operator on top of the adapter plate (Fig. 5). Rotate the gear Set Screw operator to engage the Handwheel Nut driver and align the input shaft Handwheel Nut Handwheel Handwheel and the mounting holes. Install and tighten the mounting bolts. Install the stem protector as required. Cycle the valve to ensure proper operation of the valve. For NRS valves, please contact your Zy-Gear salesperson. Installation Note *oth Adapter plate and Driver are designed to fit a specific valve. A top work dimension is needed for choosing the proper adapter plate. Consult salesperson if assistance is needed. Maintenance Zy-Gear bevel gears are equipped with grease fittings to allow for grease injection to minimize wear. Typical Gate Valve Installation Illustrated below. Adapter Plate Driver Gear Stem Protector Yoke Weld olt Fig. 1 Fig. 2 Fig. 3 Fig. 4 Fig. 5 15

16 Worm & evel Gear Operators Contact your local Zy-Tech representative for more information about Zy-Gear Gear Operators or visit our website at and view Zy-Tech s entire collection of flow control products. Your Local Representative Corporate Drive, Stafford, Texas (281) (800) Fax (281) Sales@zy-tech.com 2004 Zy-Tech Global Industries, Inc. Zy-Gear is a product of Zy-tech Global Industries, Inc. ZGI-ZG-WGOP-104