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Contents

CONTENTS .......................................................................................... 2

INTRODUCTION................................................................................ 3

GENERAL INFORMATION .............................................................. 4

HEALTH & SAFETY .......................................................................... 4

LABELS & NAMEPLATES ............................................................... 5

HANDLING & LIFTING .................................................................... 6

STORAGE ............................................................................................. 8

LONG TERM STORAGE ................................................................... 8

INSTALLATION ON VALVE ............................................................ 8

REMOVAL FROM VALVE .............................................................. 10

OPERATION ..................................................................................... 10

DISMANTLING & DISPOSAL ....................................................... 18

ROTORK SALES AND SERVICE ................................................... 18

TROUBLESHOOTING .................................................................... 19

PERIODIC MAINTENANCE .......................................................... 21

PART LIST ......................................................................................... 30

GREASE & HYDRAULIC OIL SPECIFICATION ........................ 32

This manual contains important safety information. Please
ensure it is thoroughly read and understood before installing,
operating or maintaining the equipment.

Rotork Fluid Systems reserves the right to modify, amend and
improve this manual without notice.

Rotork Fluid Systems is not responsible for damage or injury
caused by the failure to observe the instructions contained
herein.

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Summary of Contents for CQP

Page 1: ...Redefining Flow Control PNEUMATIC COMPACT ACTUATOR CQP Installation Commissioning Maintenance Manual Single Spring Version Double Acting ...

Page 2: ...OOTING 19 PERIODIC MAINTENANCE 21 PART LIST 30 GREASE HYDRAULIC OIL SPECIFICATION 32 This manual contains important safety information Please ensure it is thoroughly read and understood before installing operating or maintaining the equipment Rotork Fluid Systems reserves the right to modify amend and improve this manual without notice Rotork Fluid Systems is not responsible for damage or injury c...

Page 3: ... states have been designed built and tested according to the Quality Control System in compliance with the EN ISO 9001 2008 standard and with the following regulations directive 2006 42 EC Machinery Directive 97 23 EC Pressure Equipment Directive PED if applicable 94 9 EC Directive for safety equipment and systems to be used in potentially explosive atmospheres ATEX 2004 108 EC Electromagnetic Com...

Page 4: ...sulting from the use of the equipment for applications different from those described in the present manual Health Safety Before installing the equipment verify it is suitable for the intended application If unsure consult Rotork Fluid Systems RESIDUAL RISKS Residual risks resulting from equipment risk evaluation performed by Rotork Fluid Systems THERMAL RISKS Risk Hot Cold surface during normal o...

Page 5: ...owing label is used Figure 2 Actuator PED label It is not allowed to remove the label OPERATING LIMITS Temperature 30 C and 100 C for standard applications 20 C to 100 C for PED applications Design pressure 12 barg Do not use the equipment outside its operating limits ALLOWED FLUID TYPES The pneumatic actuator is designed to be operated with dry air or dry sweet natural gas with particles filterin...

Page 6: ...ation with the actuator lifting lugs Only lift the actuator valve assembly using the valve lifting lugs Every assembly must be estimated separately for a safe and correct lifting Avoid pulls or abrupt movements during lifting Avoid pushing the load During lifting operations do not handle the slings and or the actuator Do not step underneath suspended load LIFTING INSTRUCTIONS Note Indication of We...

Page 7: ...ange Figure 5 Holes for horinzontal lifting Install two lifting lugs of proper dimensions on apposite threaded holes on bottom and end flange lifting lugs are not provided with the actuator Hook a double chain sling on the lifting lugs as shown in Figure 6 The actuator must remain horizontal balance the load Angle β must between 0 and 45 as shown in Figure 4 Figure 6 Horizontal lifting Holes for h...

Page 8: ...alve Before proceeding read and follow out the Health and Safety information Note The pipeline valve should be properly secured prior to perform following operations according to instructions provided by the Valve s Manufacturer Prior to performing any operations check the operating drawings and TAG numbers Consult Rotork Fluid Systems for any additional information PRELIMINARY ACTIONS Verify the ...

Page 9: ... position Align the actuator adapter flange grooves according to valve coupling stem Do not exert any force while lowering the actuator onto the valve Installation must be performed by qualified personnel Hands must be kept away from the coupling area Fix the actuator to the valve by means of threaded connections bolts stud bolts and nuts Tighten the bolts or the nuts of the connecting stud bolts ...

Page 10: ...nscrew the bolts or the nuts from the stud bolts fixing the actuator to the valve Lift and remove the actuator from the valve Operation The following instructions must be followed and integrated into End User safety program when installing and using Rotork products Read and save all instructions prior to installing operating and servicing this product Follow all warnings cautions and instructions ...

Page 11: ...ves move along linear slots on the tube with vertical grooves allowing the drive shaft to transmit the rotary movement to the valve whilst preventing any rotation by the actuator piston The main components of the Compact Spring Return Actuator are shown in Figure 10 Figure 11 for type A actuators Figure 12 and Figure 13 for type B actuators Figure 10 Pneumatic Compact Spring Return Actuator Type A...

Page 12: ...olt 4 End Flange 5 Cylinder tube 6 Screws 7 Spring 8 Head flange 9 Mechanism 10 Piston Figure 13 Pneumatic Compact Double Effect Actuator Type B Threaded flanges Parts Description 1 End Cap 2 Stop nut 3 Upper stop bolt 4 End Flange 5 Cylinder tube 6 Screws 7 Head flange 8 Mechanism 9 Piston 1 2 3 4 5 6 6 7 9 8 10 1 2 3 4 5 6 7 8 9 ...

Page 13: ...s provided with a key grip to facilitate screwing unscrewing Loosen Stop nut 2 Slowly pressurize the cylinder to detach the stop bolt from the piston To reduce the actuator stroke screw stop bolt 3 To increase the actuator stroke unscrew stop bolt 3 Perform an actuator stroke to verify end position Adjust upper stop bolt again if necessary During the upper stop bolt regulation pay attention to do ...

Page 14: ... to facilitate screwing unscrewin g Verify Stop nut 2 is correctly tightened Remove the closure cap if present Use an Allen key of proper dimension to regulate the lower stop bolt Screw the lower stop bolt to reduce stroke Unscrew the lower stop bolt to increase the stroke Perform an actuator stroke to verify end position Adjust lower stop bolt again if necessary 1 ...

Page 15: ...N several times to ensure proper calibration Reassemble the box cover verifying the cover seal is correctly positioned Turn the cover shaft manually aligning it to the switch box shaft and engage it Verify if the position indicator correctly indicates the valve position Reconnect power supplies For more information refer to the limit switch manufacturer s literature Figure 16 Typical limit switch ...

Page 16: ... Figure 18 Breathing port Type A Figure 19 Inlet Exhaust port and Breathing port Type B Refer to specific operating diagram for specific application configuration Inlet port Exhaust port Breathing port Inlet port Exhaust port Breathing port ...

Page 17: ...plugs in order to guarantee sealing and to comply with explosion safety protection codes Assemble the covers of the electric components paying attention to seals Once connections have been completed check electrical components functionality START UP During the start up of the actuator it is necessary to check if Supply pressure is as prescribed The feed voltage values of electrical components sole...

Page 18: ...l energy Actuator cannot be disassembled by the End User Actuator has to be returned to the manufacturer s plant upon agreement with Rotork Fluid Systems Actuators manufactured after 1993 year do not contain asbestos or its by products Rotork Sales and Service If your Rotork actuator has been correctly installed and sealed it will give years of trouble free service Should you require technical ass...

Page 19: ...ong setting Adjust stop bolt setting following instructions in par Angular Stroke regulation page 13 5 Leakages Stop bolts wrong setting Adjust stop bolt setting following instructions in par Angular Stroke regulation page 13 Worn seals Type A actuator Replace turning flange seal Refer to PM CQP 003 and after replace piston seals Refer to PM CQP 004 Attention Do not perform PM CQP 003 and PM CQP 0...

Page 20: ...ve torque Leakage from cylinder Type A actuator Replace turning flange seal Refer to PM CQP 003 and after replace piston seals Refer to PM CQP 004 Attention Do not perform PM CQP 003 and PM CQP 004 contemporary Type B actuator Replace turning flange seal Refer to PM CQP 005 and after replace piston seals Refer to PM CQP 006 Attention Do not perform PM CQP 005 and PM CQP 006 contemporary For other ...

Page 21: ...nting Verify absence of damages Repair if necessary according to painting specification 1 Functional test 1 PM CQP 002 Check electrical components and grounding connections 1 Turning flange seals replacement Type A actuator 4 PM CQP 003 Cylinder seals replacement Type A actuator 4 PM CQP 004 Turning flange seals replacement Type B actuator 4 PM CQP 005 Cylinder seals replacement Type B actuator 4 ...

Page 22: ...ion Remove pneumatic supply before proceeding 1 Remove dust from external surfaces by blowing air Do not polish rub non metal surfaces with a dry cloth The tools and cleaning procedures must not produce sparks or create adverse conditions in the environment during maintenance operations so as to prevent potential explosion hazards Prevent electrostatic charges in potentially explosive areas ...

Page 23: ...the following test 1 Operate the actuator 2 Perform one closing stroke and one opening stroke 3 Verify actuator s movement is smooth and linear 4 Verify stroke time s are as required Actuator discharges medium gas during normal operation Pay attention during test Do not stand near exhaust port In case of stroke times out of required range refer to Troubleshooting ID 3 page 19 for solutions In case...

Page 24: ...embled or unscrewed Place the actuator on a proper bench in horizontal position Seals substitution Unscrew hex socket bolt 14 Remove turning flange 15 Remove O ring 16 Carefully clean the seals groove All the removed parts should be thoroughly cleaned inspected and de burred as necessary Replace all the mentioned seals and lubricate them with a grease film Reassembly With the actuator in horizonta...

Page 25: ...be in vertical position Hold the stop nut with a wrench then unscrew and remove cap nut 1 Remove O ring 2 Measure the distance between the upper stop bolt and the end flange 2 surface This measure will be useful during re installation Hold upper stop bolt 4 with a wrench and unscrew locking nut 5 Remove O ring 6 Unscrew and remove stopper plug 3 Remove O ring 17 Remove upper stop bolt 4 Disassembl...

Page 26: ... distance measured before Replace O ring 17 and install stopper plug 3 Install lock nut 5 with O ring 6 Screw end cap 1 with O ring 2 Final testing The actuator must be tested before it is assembled on the valve Place the actuator in a stable position e g on a workbench Connect the pneumatic supply to the actuator and cycle the actuator several times in order to check if it works smoothly and if t...

Page 27: ...tuator on a proper bench in horizontal position Seals substitution Unscrew hex socket bolt 14 Remove turning flange 15 using suitable lifting devices Remove O ring 16 Carefully clean the seals groove All the removed parts should be thoroughly cleaned inspected and de burred as necessary Replace all the mentioned seals and lubricate them with a grease film Reassembly With the actuator in horizontal...

Page 28: ...e stop nut with a wrench then unscrew and remove cap nut 1 Remove O ring 2 Measure the distance between the upper stop bolt and the end flange 2 surface This measure will be useful during re installation Hold upper stop bolt 4 with a wrench and unscrew locking nut 5 Remove O ring 6 Unscrew and remove stopper plug 3 Remove O ring 11 Remove upper stop bolt 4 Disassembly of cylinder Gradually unscrew...

Page 29: ...bolt 4 according distance measured before Replace O ring 11 and install stopper plug 3 Install lock nut 5 with O ring 6 Screw end cap 1 with O ring 2 Final testing The actuator must be tested before it is assembled on the valve Place the actuator in a stable position e g on a workbench Connect the pneumatic supply to the actuator and cycle the actuator several times in order to check if it works s...

Page 30: ...on steel 1 14 Hex socket bolt Stainless steel 8 4 Upper stop bolt Alloy steel 1 15 Turning flange Carbon steel 1 5 Stop nut Buna N 1 16 O ring Buna N 1 6 O ring Carbon steel 1 17 O ring Buna N 1 7 Hex bolt Carbon steel 10 8 Tie rod Carbon steel 10 9 End flange Carbon steel 1 10 O ring Buna N 1 11 Pneumatic Cylinder Carbon steel Nickel plated Recommended spare Number of tie rods and hex bolts could...

Page 31: ...teel 1 14 Hex socket bolt Stainless steel 8 4 Upper stop bolt Alloy steel 1 15 Turning flange Carbon steel 1 5 Stop nut Buna N 1 16 O ring Buna N 1 6 O ring Carbon steel 1 17 Pin Carbon steel 1 7 Hex bolt Carbon steel 24 8 End flange Carbon steel 9 O ring Buna N 1 10 Pneumatic Cylinder Carbon steel Nickel plated 1 11 O ring Buna N 1 Recommended spare Number of screws could be different for each sp...

Page 32: ...and internal cylinder tube for maintenance purposes Manufacturer LUBRITALIA Trade Name LUBRO GREASE L 00 Color Visual BROWN Base Oil Type MINERAL Base Oil Viscosity at 40 C DIN 51 562 150 mm2 s Soap Type LITHIUM Soap Calculated 4 Worked Penetration 60 Double Strokes ISO 2137 400 430 mm 10 Dropping Point ISO 2176 170 C Copper Strip Corrosion 24 hrs 100ºC DIN51 811 1B This is the standard grease spe...

Page 33: ...pment Rotork reserves the right to amend and change specifications without prior notice Published data may be subject to change For the very latest version release visit our website at www rotork com The name Rotork is a registered trademark Rotork recognises all registered trademarks Published and produced in Italy by Rotork Fluid Systems ROWCM1015 Rotork Fluid Systems Via del Casalino 6 55012 Ta...

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