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rotork gp series, Maintenance Manual

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rotork gp series Maintenance Manual Download Page 44

Installation, Commissioning and Maintenance 

Manual

44

PM-GP-006

Page: 7/17

Component:

 Single-Acting actuator / Double-Acting actuator

Task:

 Pneumatic cylinder and centre body seals replacement

Equipment, Tools, Materials: 

Spare seals 
Wrench
Lifting tools
Project documentation 

Warnings: 

 

Preliminary Operations: 

Removal from Valve

34. Replace yoke group (19) in the enclosure

19

35. With the help of a rubber hammer replace the axial bar (10)

10

16.0  Periodic Maintenance

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Summary of Contents for gp series

Page 1: ...GP Range Pneumatic Actuator Single Acting and Double Acting Configuration Installation Commissioning and Maintenance Manual Keeping the World Flowing...

Page 2: ...ifetime 6 6 3 Tightening Torque Chart 6 7 0 Handling Lifting 7 7 1 Lifting Recommendations 7 7 2 Lifting Instructions 7 8 0 Storage 9 9 0 Long Term Storage 9 10 0 Installation on Valve 10 10 1 Prelimi...

Page 3: ...ined for European member states have been designed built and tested according to the Quality Control System in compliance with the EN ISO 9001 2015 standard and with the following regulations directiv...

Page 4: ...on Improper use can damage the equipment or cause dangerous situations for health and safety Rotork Fluid Systems declines any responsibility for damage to people and or objects resulting from the use...

Page 5: ...acid basic solutions The following label is applied externally to the Actuator L TESTING PRESS PT DESIGN PRESS PS MAX WORKING PRESS bar bar bar L MIN MAX DESIGN TEMP TS C PED CAT FLUID VOLUME V MONTH...

Page 6: ...mum gas ignition s temperature which classifies the area with the explosion s risk Dust and debris accumulated on the actuator will slow down its cooling and contribute to the increase of its external...

Page 7: ...ls 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 7 2 Lifting Instructions Note...

Page 8: ...mmissioning and Maintenance Manual 8 Fig 7 2 Lifting double acting actuator up to size 161 Fig 7 3 Lifting single acting actuator size 200 350 Fig 7 4 Lifting double acting actuator size 200 350 7 0 H...

Page 9: ...on time If long term storage is necessary further operations must be carried out to maintain the actuator in a good working condition Replace the plastic plugs with metal plugs Stroke the actuator eve...

Page 10: ...e flange and stem they must meet the actuator coupling dimensions See document PUB083 001 Actuator is supplied in the fail position for single acting Set the valve in the right position per the actuat...

Page 11: ...mer Service To disassemble the actuator from the valve proceed as follows Cut off electrical power supply Cut off pneumatic hydraulic supply Release any pressure from the control group Remove the supp...

Page 12: ...aled housing made of welded carbon steel or in cast iron acting as a protection against corrosion and that guarantees safety of personnel during the operations Chromium plated guide bar suitable for s...

Page 13: ...uated in a perfectly sealed housing made of welded carbon steel or in cast iron acting as a protection against corrosion and that guarantees safety of personnel during the operations Chromium plated g...

Page 14: ...itable to operate the actuator in the event of fluid supply failure This device can be of mechanical screw type operated by means of a handwheel or of hydraulic type with a hydraulic cylinder operated...

Page 15: ...cting actuator Rotate the handwheel clockwise to close the valve Instructions to engage or disengage the override are reported on the plate installed on manual override Fig 12 7 Type MH manual overrid...

Page 16: ...override is type MD manual handwheel declutch able Type MD mechanical manual override Fig 12 10 Type MD Mechanical Override ENGAGE rotate lever 7 by 180 DISENGAGE rotate back lever 7 by 180 When the m...

Page 17: ...Slowly pressurize the cylinder to detach stop bolt from piston 7 E Hold stop nut 6 with a wrench F With the help of a suitable size wrench rotate the stop bolt 7 counter clockwise to increase the angu...

Page 18: ...pressure C Loosen stop nut 6 D Slowly pressurize the cylinder until setting dowel 7 is free to rotate 7 6 E To increase angular stroke rotate setting dowel 7 anti clockwise F Remove pressure G Verify...

Page 19: ...clockwise C Verify the absence of pressure D Remove cap nut 4 with seal washer 5 4 5 6 E Loosen stop nut 6 F Slowly pressurize the cylinder to detach stop bolt from piston 7 6 G To increase angular st...

Page 20: ...Stop Bolt Setting Perform the following operations as first setting Adjust the stop bolt located in the end flange of the hydraulic cylinder as follows A Verify the absence of pressure B Loosen cap n...

Page 21: ...olt Setting Perform this setting after having set the stop bolt on cylinder Adjust stop bolt screwed into the spring cartridge as follows A Pressurize the cylinder until reaching the fully open close...

Page 22: ...with a wrench F With the help of a suitable size wrench rotate the stop bolt 7 counter clockwise to increase the angular stoke G Apply pressure to port X1 X1 H Verify the newly obtained angular positi...

Page 23: ...Double Acting Actuator Centre Body Closure Flange Stop Bolt Setting Perform the following operations after cylinder stop bolt setting Adjust the stop bolt located in the centre body closure flange as...

Page 24: ...washer 2 and verify it is correctly positioned Tighten cap nut 1 2 1 12 7 8 Double Acting Actuator with HP1 Type Manual Override Cylinder Stop Bolt Setting Perform the following operations as first s...

Page 25: ...lt is normal to happen during the above procedure 12 7 9 Double Acting Actuator with Type MD Manual Override Stop Bolt Setting Perform the following operations after cylinder stop bolt setting Manual...

Page 26: ...rease angular stroke rotate stop bolt 5 clockwise 5 G Verify the newly obtained angular position with one stroke H Repeat operations A to B and F to H until the desired angle is obtained I Hold stop b...

Page 27: ...nections apply a thin layer of thread sealing product Loctite 577 or equivalent to ensure a good seal Connect the pneumatic power source in accordance to the applicable operating diagram please refer...

Page 28: ...ries On the unused entries of the junction box replace the plastic plugs with approved metal plugs to guarantee sealing and comply with explosion safety protection codes Assemble the covers of the ele...

Page 29: ...ast iron and aluminium alloys as metal scraps Dispose of the rubber PVC resins etc separately in accordance with the existing national and regional regulations Electric components are to be separately...

Page 30: ...ng Adjust stop bolt setting following instructions in ANGULAR STROKE SETTING page 17 5 Leakages Stop bolts wrong setting Adjust stop bolt setting following instructions in ANGULAR STROKE SETTING page...

Page 31: ...by Manual Override 1 PM GP 003 Check electrical components if present and grounding connections 1 PM GP 004 Check threaded connections bolts studs and nuts with valve If necessary tighten to the reco...

Page 32: ...s Warnings Preliminary Operations Description Remove electric and pneumatic supply before proceeding 1 Remove dust from actuator external surface by dust rag and by blowing air Do not polish rub non m...

Page 33: ...rform the following test 1 Operate the actuator 2 Perform the stroke several times by local and remote if applicable control Actuator could exhaust medium supply in the atmosphere during normal operat...

Page 34: ...tor is in its fail position spring relaxed for Single Acting actuator 3 Move the mechanical manual override according to instructions reported in MANUAL OVERRIDE page 14 to stroke the actuator 4 Verif...

Page 35: ...pply before working on electrical devices Read and follow the safety precautions reported in the Manufacturer s Maintenance Manual Risk of temporary modification of the component protection Use only a...

Page 36: ...d hydraulic fluid must be disposed of safely D1 A2 Filling procedure 7 Fill with oil from the fill breather port 1 5 up to 25 mm 1 below the port 8 Close stop valve 1 2 and verify that stop valve 3 is...

Page 37: ...l breather port 1 5 up to 25 mm 1 below the port 25 Move the open close selector 1 2 to the outboard side of the hydraulic cylinder 26 Install the pump lever and operate pump 1 1 until oil is bled fro...

Page 38: ...rsonnel Preliminary actions 1 Remove actuator from valve par Removal from Valve page 11 2 Position the actuator on a workbench if possible or in a stable position and in a clean and closed area 3 Remo...

Page 39: ...ls Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 11 Unscrew screws 1 and remove position indicator 2 with gasket 3 12 Unscrew bolts 5 and pa...

Page 40: ...cartridge adequately 16 Unscrew bolts D carefully The spring cartridge module can exert a thrust against the centre body Unscrew bolts D gradually all at the same time to release the spring energy D 1...

Page 41: ...2 Position the actuator vertically on a workbench 23 Secure the actuator to the workbench with suitable clamps 24 Hook the cylinder with suitable textile sling 25 Unscrew set screw 16 from guide block...

Page 42: ...dy seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 30 Remove O ring 18 from cover bushing 17 clean...

Page 43: ...seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 32 Remove yoke group 19 from enclosure 19 33 Remov...

Page 44: ...r Task Pneumatic cylinder and centre body seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 34 Repla...

Page 45: ...seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 36 Position the cylinder vertically on suitable w...

Page 46: ...cement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 39 Unscrew nuts 8 40 Remove end flange 11 with O ring 2 41 Re...

Page 47: ...nscrew nut 14 45 Disassemble washer 15 and piston 27 from the piston rod 23 46 Remove Sliding ring 28 and O ring 29 from the piston 47 Remove shoulder washer 16 15 16 23 14 28 29 27 48 Unscrew screws...

Page 48: ...Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 54 Position O ring 19 on its seat 55 Position seal retaining flange 18 and tighten screws 17 17 18 19 56 Clean th...

Page 49: ...replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 59 Replace sliding ring 28 and O ring 29 on piston 27 2...

Page 50: ...cylinder and centre body seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 63 Restore flange 9 with...

Page 51: ...pare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 67 Rotate the cylinder clockwise to screw piston rod 23 into guide block 14 68 Lock with set sc...

Page 52: ...ons valid only for SINGLE ACTING ACTUATOR 72 Apply a film of Loctite 243 on bolts D and tighten to the recommended torque following a cross bolt tightening sequence Lubricate the sliding components of...

Page 53: ...ement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 76 Replace O ring 7 77 Position the cover 6 on the centre body...

Page 54: ...tening both the stop nut 6 and the cap nut 4 always make sure the two washers 5 are correctly positioned Please refer to page 17 of the present document for the instructions to regulate the stop bolt...

Page 55: ...ric power supply if present before performing any operation Preliminary actions 1 Verify actuator is in the fail position single acting and not pressurized 2 Remove actuator from valve par Removal fro...

Page 56: ...eplacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 11 Measure length W W 12 Hold stop bolt 3 with a wrench a...

Page 57: ...rride seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 16 Remove hydraulic cylinder assembly from p...

Page 58: ...anual override seals replacement Equipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 19 Unscrew bolts 6 6 20 Remove end...

Page 59: ...g tools Project documentation Warnings Preliminary Operations Removal from Valve 23 Remove sliding ring 11 and O ring 12 11 11 12 24 Remove O ring 9 back up ring 10 and piston rod seals 16 from the he...

Page 60: ...Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 29 Assemble sliding ring 11 and O ring 12 on piston 13 11 11 12 30 Install O ring 9 back up ring 10 and piston r...

Page 61: ...s Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 34 Assemble end flange and tighten nuts 6 to the recommended tightening torque 6 35 Assemble O ring V3 a...

Page 62: ...quipment Tools Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 38 Assemble seal washer 2 in its correct position and stop bolt 3 to...

Page 63: ...Materials Spare seals Wrench Lifting tools Project documentation Warnings Preliminary Operations Removal from Valve 41 Assemble hydraulic pump 3 with its support and tighten bolts S 42 Install pipe P...

Page 64: ...DESCRIPTION QTY 1 O ring 1 18 Screw 2 2 Guide bar bushing 2 19 Screw 17 3 Yoke bushing 1 20 Set screw 2 4 Yoke bushing 1 21 Circlip 2 5 Sliding block 1 6 Sliding block 1 7 Guide bar 1 8 Guide block 1...

Page 65: ...ew 2 18 O ring 2 2 Position indicator 1 19 Scotch yoke 1 3 Position indicator gasket 1 20 Lower bushing 1 4 Parallel pin 2 21 Screw 4 5 Screw 15 22 Gasket 2 6 Cover 1 7 O ring 1 8 Housing 1 9 Safety v...

Page 66: ...TION QTY 1 Screw 2 18 O ring 2 2 Position indicator 1 19 Scotch yoke 1 3 Position indicator gasket 1 20 Lower bushing 1 4 Parallel pin 2 21 Screw 4 5 Screw 22 Gasket 2 6 Cover 1 7 Cover gasket 1 8 Hou...

Page 67: ...sher 2 19 Parallel pin 2 3 Position indicator seal 1 22 O ring 4 4 Guide bar bushing 2 23 O ring 2 5 Washer 4 24 Screw 2 6 Safety valve 1 25 Set screw 2 8 Housing 1 27 Screw 2 9 Yoke bushing 2 28 Scre...

Page 68: ...g 2 18 Yoke pin 1 2 Washer 2 19 Insert 2 3 Position indicator gasket 1 20 Guide block 1 4 Safety valve 1 22 Parallel pin 2 5 Cover 1 25 O ring 2 6 Lower bushing 1 26 Screw 1 7 Upper bushing 1 27 Screw...

Page 69: ...Stop nut 1 22 Centring ring 1 7 Stop bolt 1 23 Piston rod 1 8 Nut 24 Screw 9 Adapter flange 1 26 Cylinder tube 1 10 O ring 1 27 Piston 1 11 Lifting plate 2 28 Sliding ring 1 12 Tie rod 29 Piston seal...

Page 70: ...t 1 22 Centring ring 1 7 Stop bolt 1 23 Piston rod 1 8 Nut 24 Screw 9 Adapter flange 1 25 Cylinder tube 1 10 O ring 1 26 Piston 1 11 Lifting plate 2 27 Sliding ring 1 12 Long Tie rod 28 Piston seal 1...

Page 71: ...et 1 3 Head flange 1 4 Bushing 1 5 Spring driving flange 1 6 Elastic pin 8 7 Stop bolt 2 8 Rod 1 9 Washer 1 10 Nut 1 11 End flange 1 12 Seal washer O ring 2 13 Plug 1 14 Spring container 1 15 Spring R...

Page 72: ...body closure flange Fig 17 9 Centre body closure flange ITEM DESCRIPTION QTY 1 Cap nut 1 2 Seal washer O ring 2 3 Stop nut 1 4 Nut 5 Stop bolt 1 6 Flange 1 7 Screw 8 Guide block plug 1 9 Gasket O rin...

Page 73: ...washer O ring 2 17 Head flange 1 3 Stop nut 1 18 Hex bolt 4 4 Stop bolt 1 19 Adapter flange 1 5 End flange 1 20 Screw 8 6 Nut 21 Plug 4 7 Tie rod 22 Washer 4 8 Cylinder tube 1 23 Silencer 9 O ring ba...

Page 74: ...DESCRIPTION QTY 1 Handwheel 1 2 Jackscrew 1 3 Screw Washer 1 4 Nut 1 5 Setting dowel 1 6 O ring 1 7 Adapter Flange 1 8 Back plate 1 9 Bearing 1 10 Slotted spring pin 1 11 Front plate 1 12 O ring 1 13...

Page 75: ...2 17 Handwheel 1 3 Stop nut 1 18 Ring nut 1 4 Stop bolt 1 19 Scraper ring 1 5 Wheel Hub 1 20 O ring 1 6 Key 2 21 O ring 1 7 Screw 3 22 Closure flange 1 8 Ring switch 1 23 End cap 1 9 Protection pipe 1...

Page 76: ...21 Parallel pin 1 4 Stop bolt 1 22 Flange 1 5 Handwheel 1 23 O ring 1 6 Washer 2 24 Activator 1 7 O ring 1 25 Hex bolt 1 8 Ring 1 26 Spindle nut 1 9 Bush 1 27 Spindle nut fork 1 10 O ring 1 28 Screw 1...

Page 77: ...360 mm2 s Service temperature Drop point ISO 2176 40 to 230 C 40 to 446 F None Four ball tester Weld load Din 51 350 pt 4 Wear scar under 800N load Din 51 350 pt 5 3000 N 0 94 mm Coefficient of frict...

Page 78: ...k Fluid Systems hydraulic manual override and hydraulic cylinders working at temperature between 20 C and 100 C for ATEX and non ATEX application Manufacturer MOBIL Trade Name DTE 10 EXCEL 32 ISO Visc...

Page 79: ...03 Pass This is the standard oil specification for Rotork Fluid Systems hydraulic manual override and hydraulic cylinders working at temperature down to 60 C for non ATEX applications Manufacturer MOB...

Page 80: ...ntinually developing our products their design is subject to change without notice The name Rotork is a registered trademark Rotork recognises all registered trademarks Published and produced in the U...

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