INSTALLATION, COMMISSIONING AND MAINTENANCE MANUAL MM-018-1-E

DOUBLE ACTING GAS OVER OIL ACTUATORS

GO SERIES

Rev. 00 01 02

Description Issue Section B - Par. 1 revised Sections (B – E –F) revised

Pages 45 45 47

Date 24.03.05 20.07.05 15.02.06

Issued by Cocliti Cocliti Cocliti

Approved by Pisaroni Pisaroni Pisaroni

Rotork Fluid System S.r.l Via del Casalino, 6 55012 Tassignano, Lucca - Italy

tel. (+39) 0583.93061 fax (+39) 0583.934612 http://www.Rotork .com E-mail: fluid@fluidsystem.it

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File GO_INDEX

INDEX


INTRODUCTION
SECTION (A) GO series actuator description SECTION (B) Checks to be carried out upon delivery Storage Safety Considerations Instructions for assembling the actuator onto the valve SECTION (C) Setting of angular stroke SECTION (D) Setting of electric limit switches SECTION (E) Arrangement for start-up and actuator/line connections Start-up Line break SECTION (F) Maintenance and instructions for changing oil in the tanks Gas / oil tanks oil filling instructions and hydraulic circuit purge SECTION (G) Replacement of cylinder seals SECTION (H) Lubrication Hydraulic oil features SECTION (I) Typical sectional drawings and parts-list SECTION (L) Instructions for actuator lifting SECTION (M) Operating instructions for electric control systems Features of the Rotork limit switch box type MB1

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INTRODUCTION
File GO_INTR.

This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid System GO Range actuators. It is users responsibility to follow the instructions in this manual as well as any additional documentation that has been supplied regarding the actuator or the accessories supplied by Rotork Fluid System. Should further information or guidance concerning to the safe use of GO Range actuators be required, it will be provided up on request. Users are also to be familiar with and follow any relevant legislation or statutory provisions regarding health and safety. It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or on the equipment are properly trained for the work they are performing and are also aware of their responsibilities related to health and safety in the workplace. It is extremely important that precautions be taken to avoid spark or static discharge in any areas of potentially explosive atmosphere. All Rotork Fluid System actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test certificates and replacement documentation are available upon request. The latest general information regarding any Rotork product is available on our website www.rotork.com.

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S E C T
Par. 1. – GO series actuator description

I O N

(A)

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File GO_DESC GO SERIES ACTUATOR DESCRIPTION SECTION (A) . In case of a rack and pinion type. while the stop bolt for the adjustment of the closed position of the valve is screwed into the cylinder used to open the valve. The main components of these units are the following: GO scotch yoke series: GO-65. Hydraulic oil contained in the tank is pressurized by gas and flows into the respective cylinder chamber. In both series. position transmitter etc. GO-271 A scotch-yoke mechanism (see table DSGA006) which transforms the linear movement of the hydraulic cylinder into a rotary movement suitable to operate quarter turn valves such as ball valves. the stop bolt for the adjustment of the open position of the valve is screwed into the center body closing flange. the mechanical visual indicator showing the valve position during the stroke of the actuator is directly connected to the valve stem. which protects it against corrosion and guarantees safety to the personnel during the operations. It is also fitted with a guide bar suitable for supporting the transverse forces. Two opposed hydraulic cylinders (see table DSRE004). In particular. The relevant piston is made of carbon steel with dynamic seals realized in Buna-N and PTFE. GO-130. GO-200. GO-240 A rack and pinion mechanism (see table DSRA001) which transforms the linear movement of the hydraulic cylinders into a rotary movement suitable to operate quarter turn valves such as ball valves. there are two mechanical stops to enable the adjustment of the valve angular stroke by means of stop bolts. while the oil contained in the other chamber flows into the second tank. 1 GENERAL DESCRIPTION The GO series actuator is gas over oil double acting actuator. while the stop bolt for the adjustment of the closed position of the valve is screwed into the bottom flange of the hydraulic cylinder. such as signalling limit switches. the guide bar is chromium plated in order to guarantee its protection against corrosion.Par. The piston is made of carbon steel with dynamic seals realized in Buna-N and Teflon. made of carbon steel. to guarantee a long working life. butterfly valves or plug valves. In both series. the stop bolt for the adjustment of the open position of the valve is screwed into the cylinder used to close the valve. butterfly valves or plug valves. that protects it against corrosion and that guarantees safety the personnel during the operations. The rack and pinion mechanism is made of alloy steel and is included into a perfectly sealed housing. made of welded carbon steel. gas flows into the tank through the control valves with respect to the operation (opening or closing) to be performed. GO-201 GO-270. fed by pressurized gas. The scotch-yoke mechanism is included into a perfectly sealed housing. to ensure the proper alignment of the piston rod and with bronze sliding blocks and yoke bushing suitable for reducing the friction. GO-85: GO-100. The cylinder tube is nickel plated internally. The cylinder tube is nickel plated internally. GO-120. In case of a scotch yoke type. If required. GO-60. The design characteristics are shown on the data plate attached to the actuator. GO-30. the GO series actuators may also be supplied complete with accessories. in order to reduce roughness of the surface to a minimum value and to provide highest protection against corrosion. These actuators are fitted with a hydraulic emergency manual override and operated by means of two hydraulic hand pumps. The cylinder piston stroke triggers the operation of the actuator. Hydraulic cylinder (see table DSGE119). There are two types of Rotork Fluid System actuators of GO series: the scotch yoke and the rack and pinion series. After being filtered. GO-160 GO-161. made of nodular cast iron. 5 . GO rack and pinion series: GO-15. made of nodular cast iron. in order to reduce roughness of the surface to a minimum value and to provide highest protection against corrosion.

S E C Par. 2.Checks to be carried out upon delivery T Par. .Storage I Par. . 4. . 3.Instructions for assembling the actuator onto the valve N (B) 6 . . 1.Safety Considerations O Par.

Order number .1 DAMAGE DURING TRANSPORT Upon delivery. SETTING OF MECHANICAL STOPS AND LIMIT SWITCHES In the event that the actuator has been delivered already assembled onto the valve. the setting of the mechanical stops and electric limit switches (if foreseen). if necessary.File CHECK_04 CHECKS TO BE CARRIED OUT UPON DELIVERY SECTION (B) . the mechanical stops and electric limit switches (if foreseen) have already been set during assembling. the following plates will be placed.Tag number. . .Min/max operating pressure. in the test certificate and in the delivery note. repair the possible damages to the paint-work.Par. 7 .Model. .Serial number. In the event that the actuator has been delivered separately from the valve. . check if the actuator has been damaged during transport and. DATA PLATE The following information are contained on the actuator data plate: . must be carried out after the assembling of the actuator onto the valve according to the instructions stated herein under the applicable paragraph of sections (C) and (D). in line with the directives: ATEX 94/9/CE PED 97/23/CE Please make sure that information printed on the data plate are in conformity with those specified in the order.Month / year of manufacture. CE MARK: Where applicable. ACCESSORIES When the supply includes accessories. please check if they are in conformity with those listed in the order and in the shipping documents.

Actuators awaiting to be assembled onto the valves. examine the electric connections and terminals to make sure that they are clean and free from oxidation and humidity. Control panel functionality must also be verified. LONG-TERM STORAGE In case of storage for over 12 months. or nominated hydraulic mineral oil with NAS 1638 class 6 as minimum cleanliness level in case of hydraulic actuators. further operations must be carried out to maintain the actuator in a good working condition. In order to keep the actuators in a good condition until they are assembled on the plant. must be placed onto wooden pallets. all the threaded connections of the actuator and the control panel are to be carefully closed. etc. 8 . The tightness and the functionality of the seals must be checked every 6 months.) with grease or protective oil.File STORAGE _01 STORAGE SECTION (B)-Par. All seals must be changed after 3 years of storage. dehydrated and lubricated air in case of pneumatic actuators. flange.2 GENERAL INSTRUCTIONS The actuators leave the Rotork Fluid System factory in excellent finishing and working conditions. Subsequently. as guaranteed by the inspection certificate issued for each single actuator. Protect the coupling parts (adapter and coupling joint. during the period of storage: Check if the plugs have been properly assembled on the fluid and electric connections. we recommend that the following measures be taken. so as to prevent any damage on the valve coupling flange. Also check the tightness of terminal screws. using filtered. While checking the functionality of the panel and the actuator. namely: The actuator must be stroked on a 6-month basis. in order to prevent dust/sand/water from entering during transport and storage. Keep the actuators in a dry place or provide protection against the direct effect of weather agents.

retighten the stop nuts. the pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. then return it to check position. It is usual however to align the centreline of the cylinder to the centreline of the associated pipe work.1 MAXIMUM ALLOWABLE TEMPERATURE The maximum temperature allowable for standard build actuators is 100°C (212°F). Tighten as required.g. Ensure there are no leaks from any pneumatic or hydraulic connections.4. Certain valves incorporate their own stops. in the case of sites where a potentially explosive atmosphere may exist.3 3.2. When the actuator has been bolted to the flange or adapter. If the unit has a nameplate indicating that it is suitable for installation in a potentially explosive atmosphere (hazardous area). lightning strikes. or the protection afforded by the actuator. 3. vibration sources and vehicular movement. 3. the user must ensure the actuator is suitably protected against its operating environment including. Once in position. The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment per the guidelines set forth in EN 1127-1 par 6. When the correct positioning is obtained. If uneven operation occurs. In these cases it is recommended that the actuator stop bolt positions coincide with the valve stop positions. Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply fluid will affect actuator temperature. If these end of travel positions are not correct. Ensure tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the dynamics of the pipeline. Contact Rotork Fluid System if in doubt. it must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the nameplate.3 MECHANICAL CONSIDERATIONS It is recommended that before lifting an actuator onto a valve.2 OPERATING ENVIRONMENT The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the safe use of. require proper orientation with respect to gravity to function properly. but not limited to. These could throttle the flow thus reducing the pressure and volume at the actuator and causing intermittent motion. Stroke the yoke away from the stop bolt when adjusting. 9 . great care is taken to ascertain the position of the valve and orientate the actuator accordingly.. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the nameplate is not exceeded and also. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures. Rotork actuators can be mounted on valves in almost any desired position. that the surface temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere. Flow may be restricted by undersize pipe or fittings. filter drains. Ensure all fasteners are adequately tightened to avoid loosening during the course of operation. Other maximum temperature build options are available. the actuator should operate the valve with a smooth continuous action. the stop bolts may be adjusted by first loosening the stop nuts and then screwing the bolts in or out until desired end position is obtained. the position of the stop bolts should be checked to ensure full opening and closing of the valve. hydraulic reservoirs. All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris.SAFETY CONSIDERATIONS File SAFETY_01 SECTION (E)-Par. Where appropriate. Note: Certain accessory and control components e. taking into account vibration induced by the dynamics of the pipeline.

Lift the actuator by connecting the sling to the support points of the actuator. The assembly position of the actuator must be in accordance with plant requirements and with the valve model.Par. on rack and pinion models) or into the groove of the coupling joint. Clean the coupling flange of the actuator and remove anything that might prevent a perfect adherence to the valve flange. without exercising any force and only with the weight of the actuator. 10 . In this case the actuator must be lifted while the coupling flange is kept in the horizontal position.using the actuator housing flange with threaded holes. .File GO_ASSY INSTRUCTIONS FOR ASSEMBLING THE ACTUATOR ONTO THE VALVE SECTION (B) . Make sure the sling is suitable for the weight of the actuator. Make sure grease has been perfectly removed. Fasten the actuator to the valve by tightening the nuts of the connecting stud bolts. If possible. assemble the latter onto the valve stem before proceeding with the assembling of the actuator. Lubricate the valve stem with oil or grease. operate the actuator in order to check whether the valve is actuated smoothly. In order to assemble the actuator onto the valve. Lower the actuator onto the valve so that the valve stem slips in the actuator yoke (or in the actuator pinion.interposing an adapter and a coupling joint. according to the actual position of the actuator. Clean the coupling flange of the valve and remove anything that might prevent a perfect adherence to the actuator flange. If the assembling is carried out by means of a spool piece together with a coupling joint. Make sure grease has been perfectly removed. to facilitate assembling. Set the valve in the open or closed position. place the valve stem in a vertical position to facilitate assembling.4 The assembling of the actuator onto the valve can be performed by: . If possible. proceed as follows: Make sure that the coupling dimensions of the valve flange and stem meet the actuator coupling dimensions.

Setting of angular stroke I O N (C) 11 . .S E C T Par. 1.

Repeat this operation until the desired angle is obtained. Repeat this operation until the desired angle is obtained. 1.Remove the cap nut (item 1).Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to obtain the detachment of the piston (item 6) from the stop bolt (item 2).Tighten the lock nut (item 4).2 .Loosen the lock nut (item 4). Screw or unscrew the stop bolt (item 2) and verify. Screw or unscrew the stop bolt (item 2) and verify. 12 .1 .4 .Pressurize the hydraulic cylinder (moving the valve towards closing position) in order to obtain the detachment of the plug for the guide block (item 5) from the stop bolt (item 2). with one closing stroke. Note: Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston (item 6).Reassemble the cap nut (item 1). as follows: 2.4 .1 . 2. 2. as this may cause fluid pollution.5 .5 .Remove the cap nut (item 1).Loosen the lock nut (item 4). with one opening stroke the newly obtained angular position.Tighten the fixing nut (item 4).SETTING OF THE ‘OPEN VALVE’ POSITION Adjust the stop bolt which is screwed into the closing flange of the center body.2 . the newly obtained angular position. 1 .3 . 1.File GO_AST SETTING OF ANGULAR STROKE (Scotch yoke actuator series) SECTION (C)-PAR. Certain valves incorporate their own stops.SETTING OF THE ‘CLOSED VALVE’ POSITION Adjust the stop bolt which is screwed into the end flange of the hydraulic cylinder as follows: 1. 1. 2. 1. For such valves it is recommended that the actuator stop bolt positions coincide with the valve stop position. 2.Reassemble the cap nut (item 1).3 . During this operation there will be a small loss of oil through the thread of the stop bolt (item 2).1 The angular stroke is set by adjusting the stop bolts which are screwed into the end flange of the hydraulic cylinder and in the housing closing flange. 2 .

Repeat this operation until the desired angle is obtained. Note: Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston (item 5).4 .3 .Loosen the lock nut (item 4). 1.SETTING OF THE ‘OPEN VALVE’ POSITION Adjust the stop bolt which is screwed into the hydraulic cylinder for close operation.2 . the newly obtained angular position. 1.5 .4 . 2.Reassemble the cap nut (item 1). 1 . 1.File GO_AST SETTING OF ANGULAR STROKE (Rack and pinion actuator series) SECTION (C)-PAR.1 . 1. 2.Tighten the fixing nut (item 4). 2.1 The angular stroke is set by adjusting the stop bolts which are screwed into the hydraulic cylinders. with out one closing stroke.Pressurize the hydraulic cylinder (moving the valve towards the closing position) in order to obtain the detachment of the piston (item 5) from the stop bolt (item 2).2 .Remove the cap nut (item 1).Reassemble the cap nut (item 1). with one opening stroke.3 . as follows: 2.SETTING OF THE ‘CLOSED VALVE’ POSITION Adjust the stop bolt which is screwed into hydraulic cylinder for open operation as follows: 1. For such valves it is recommended that the actuator stop bolt positions coincide with the valve stop position. 2 . During this operation there will be a small loss of oil through the thread of the stop bolt (item 2). the newly obtained angular position. 2. Certain valves incorporate their own stops. as this may cause fluid pollution. During this operation there will be a small loss of oil through the thread of the stop screw (item 2).Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to obtain the detachment of the piston (item 5) from the stop bolt (item 2).Loosen the lock nut (item 4).Tighten the lock nut (item 4).1 . Screw or unscrew the stop bolt (item 2) and verify. 13 .Remove the cap nut (item 1). Screw or unscrew the stop bolt (item 2) and verify. Repeat this operation until the desired angle is obtained.5 .

1.S E C T Par. .Setting of electric limit switches I O N (D) 14 .

1 Unscrew the four screws (item 1). remove the cover and proceed in line with the above mentioned items a. a. a.SETTING OF MECHANICALLY OPERATED ELECTRIC LIMIT SWITCHES ASSEMBLED INTO THE LIMIT SWITCHES BOX.3 Tighten the dowel (item 5). repeat the above operations for all the remaining limit switches.3 up to a.Par. b. arrange the actuator in the required position of the valve (fully closed or fully open).SETTING OF THE CLOSING LIMIT SWITCH Place the actuator in the fully closed position of the valve. a. 1. b. 1 In case the actuator is provided with limit switches their setting should be performed by the user during the actuator testing operations on the valve. a.1 up to b.5 (or b. b.SETTING OF THE OPENING LIMIT SWITCH Place the actuator in the fully open position of the valve.1 . b.4 Rotate the cam in order to operate the limit switch.2 Remove the cover (item 2).5 Tighten the dowel (item 5).1 Loosen the dowel (item 5) of the cam (item 4) which operates the opening limit switch.4).2 . 15 . 1 .4 Reassemble the cover (item 2) and screw the four screws (item 1).2 Rotate the cam in order to operate the limit switch. which operates the closing limit switch.File LSW_01 SETTING OF ELECTRIC LIMIT SWITCHES SECTION (D) . a. 1.3 Loosen the dowel (item 5) of the cam (item 4). NOTE Should the electric switches box be fitted with a single limit switch. Should the electric switches box be fitted with more than 2 switches.

SETTING OF THE OPENING LIMIT SWITCH Place the actuator in the fully open valve position. b.File LSW_01 SETTING OF ELECTRIC LIMIT SWITCHES SECTION (D) .1 and a.SETTING OF THE CLOSING LIMIT SWITCH Place the actuator in the fully closed position of the valve. Slide it axially and vary the positioning distance between the electric limit switch and the operating cam. 2.1 .1 Unscrew the four screws (item 1) and remove the cover (item 2). Tighten the fixing nuts. rotate the cam by placing it on the same axis of the electric limit switch.3 operating on the cam and on the opening electric limit switch.Par.2 .1 Proceed according to the above mentioned points a.3 In order to adjust the switching point of the electric limit switch.2 Loosen the dowel (item 5) of the cam (item 4) which operates the closing electric limit switch. loosen its fixing nuts. a. b.SETTING OF PROXIMITY LIMIT SWITCHES ASSEMBLED INTO THE LIMIT SWITCHES BOX 2. 1 2 .2 Reassemble the cover (item 2) and screw the four screws (item 1). a. 16 . a.

– Line break technical information N (E) 17 . 2.Arrangement for start-up C T Par. 1.Start-up I O Par. 3.S E Par. . .

pneumatically powered actuators may exhaust the power supply gas to atmosphere in the course of normal operation.. Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e. filtration. in order to avoid possible damages to the actuator itself or loss of performance. In accordance with the operating diagram.g. the gas line can be connected to the control panel in the following two ways: 1 Directly to the shuttle valve (item 17). in case the system undergoes strong vibrations. Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium. Note: Depending upon control circuit design. This may present an unacceptable hazard in some applications. Also make sure that its operating times are in accordance with those specified in the test certificate and that there aren’t any leakages in the gas/hydraulic connections. 1. natural gas). hydration) corresponds to that for which the actuator was manufactured.2 ACTUATOR / LINE CONNECTIONS Before connecting the actuator to the gas supply line. Consult Rotork Fluid System if in doubt as to the suitability of the equipment supplied for your application. in order to guarantee the gas flow required for the operation of the actuator and to avoid that supply pressure drops below the minimum allowable value. 17 X1 X2 17: Gas shuttle valve (supply) X1-X2: 1/4 NPT (Female) Gas connections 18 .1 1. Take every precaution to remove any solid or liquid foreign matter from the pipe work into the actuator.. make sure that pipes and fittings are according to the applicable plant specifications. Once the gas connections have been completed. Clean the inside of the pipes used for connection by washing them with suitable detergent and by blowing air into them. Fasten the piping properly. operate the actuator and check if it works correctly. Verify that medium composition (e. so as to prevent the loosening of threaded connections.g.1 MOTIVE POWER SUPPLY Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as indicated on the nameplate.File ARRANGE_GO ARRANGEMENT FOR START-UP SECTION (E)-Par.

carbon steel/stainless steel.D. follow the instructions below: 27 K1 K2 K1: 1/4" NPT (female) .File ARRANGE_GO ARRANGEMENT FOR START-UP SECTION (E)-Par.Pilot gas connection . suitable for pressure as per applicable plant specification.1 2 Indirectly to the shuttle valve (item17).downstream K2: 1/4" NPT (female) .upstream 19 .low pressure . follow the instructions below: 23 K K: 1/2” NPT (Male) or 1/4" NPT (Female) .Pilot connection In case the control panel is provided with an adjustable pilot differential (item 27). In case the control panel is provided with a low pressure sensor (item 23). via 2 isolation filters (items 19) and isolation valves (items16) 16 16 17 19 19 X1 TO PANEL X2 16: Isolation valve 17: Gas shuttle valve 19: Filter (supply) X1-X2: 1/4 NPT (Female) Gas connections The suggested tubing between actuator and main pipe (at user is care) is: O.Pilot gas connection . 12 mm rigid tube 1mm thickness.high pressure .

20 . Access to live electrical conductors is forbidden in hazardous areas unless done under a special permit. Connection documentation is supplied with the actuator. Seal unused cable entries with a steel or brass plug. Make sure that the components used for electrical connections (such as cable hose conduits. Any electrical connections required are the responsibility of the user. Only appropriate certified explosion-proof entry reducers. cable glands) are in accordance with the requirements and codes applicable to the plant. Remove the plugs from the cable entries. cable glands or conduit are tight and fully waterproof. On the unused entries of the pull box. Make cable entries appropriate to the cable type and size. Electric connections are to be made by using rigid conduits and trailing cables so as to prevent anomalous mechanical stresses in the cable entries. replace the plastic plugs with the metal ones. and lightning strikes as well as magnetic or electro-magnetic fields. This is the responsibility of the user. all power should be isolated and the unit moved to a non-hazardous area for repair or attention. by linking them up with the terminal blocks of electric components in accordance with the applicable wiring diagram. solenoid valves. etc. In hazardous areas an appropriately certified threaded blanking plug must be used. Verify that the electrical supply characteristics are compatible with the supplied actuator control components. Otherwise. Ensure that threaded adaptors.File ARRANGE_GO ARRANGEMENT FOR START-UP SECTION (E)-Par.). Refer to the applicable wiring diagram to identify functions of terminals. Once connections have been completed. glands or conduit may be used if the unit is installed in a hazardous area. with reference to mechanical and/or explosionproof protection. control and signal lines to the actuator. Connect the electric feed. The actuator and control components must be protected from electrical sparks. in order to guarantee perfect seal and to comply with explosion safety protection codes (where applicable). check if controls and signals work properly.3 ELECTRIC CONNECTIONS The following instructions are applicable to actuators provided with electric accessories (such as limit switches. surges.1 1. Remove any plastic transit plugs.

if applicable) are as prescribed.File STARTUP GO START-UP SECTION (E) . gas supply pressure. is as prescribed. etc.. such as remote control. Feed voltage values of electric components (solenoid valves coils. 21 . limit switches.2 During the start-up of the actuator.) are correct. assembling or storage operations. emergency control (if applicable). Gas/hydraulic connections show any leakage. The required remote signals (such as valve position. pressure switches etc. If necessary. it is necessary to check if: The oil level in the gas/oil tanks is in accordance with the instructions brought in the “section F” paragraph 2. etc. tighten the nuts of the pipe fittings. In case the control panel is provided with a local/remote selector valve (18) may be positioned by means of manual levers located on the poppet valves (4a and 4b) for LOCAL control or by means of the solenoids (5a and 5b) for REMOTE control.Par. The painted parts have been damaged during transport. local control. Gas supply pressure. The setting of the actuator control unit components is according to the requirements of the plant. Actuator controls. work properly. repair the damaged parts following the painting specification. Having removed rust.

as the line would have to be closed. They need to have their own source of energy. it must be as low as possible to detect remote failures. 22 . directly from the line pressure. in order to prevent gas leakage due to pipeline breaking. adjustable differential pressure switch (40). Therefore. In fact. the pipe line dimensions.e. 3/2 pilot manual reset valve (41). 40 35 36 41 32 37 10 34 FUNCTIONALITY DESCRIPTION: Due to the fact that many Line-break detectors (RLD) have been mounted as a protection on the gasline . check valve (35). the greater the distance the lower the speed). In case of pipeline break down.3 INTRODUCTIONS: The Rotork Line-Break system detector (RLD) is designed to close the valves automatically in case pre-determined pressure drop rate is exceeded. they are placed in countryside areas. A compromise must also be made in adjusting the pressure drop speed setpoint. gauges (10) filters (32-37) and stop valves (31-34). the gas density. increase/decrease of gas users). Under normal working conditions.File linebreak GO LINE-BREAK TECHNICAL INFORMATION SECTION (E) . calibrated orifice (36). far away from stations and cities. Line-break devices ought to be easily regulated to meet different working conditions and all the characteristics of the line.g. the dimensions and the type of failure. The RLD has to be connected to the pipeline downstream from the main valve so as to avoid undesirable closing operations during the opening of the valve because pressure drops quickly in the upstream line during this operation. gas pressure will be steady or it will slowly change due to many factors (e. the location of the failure (upstream or downstream) and the distance from the break (i. but not too close to the normal variation of the pipeline pressure.Par. the variation of pressure drop will depend on the absolute pressure. The RLD system (see the control schematic) includes the followings components: reference tank (33).

1 1.2 up to 4 Barg by rotating the relevant pommel nut referring to the indicator scale. the smaller the orifice. The faster the drop rate in the pipeline.4mm orifice.1 0. with the 0.25 0 0 0.4 0. 23 ∆P ( Bar ) for NATURAL GAS at 20 °C . 25 Bar Pres.8 0.9 1 1.3 0. 75 Bar Pres. FIGURE 1 Curves related to maximum ∆P acting upon the pressure switch at differential initial pressure and at differential pressure drop rate.Par. it remains higher in the tank than in the line because the check valve closes and the gas flows back into the pipeline through the orifice only.8 mm diameter calibrate orifice hole.5 3.2 1. 45 Bar Pres. gas flows through the check valve (35) and orifice (36). The value of the ∆P for the operation of the adj. it is necessary to reset the valve (41) with the relevant manual reset.25 4 3. into the reference tank (33).4 1.4 mm (Time from 2 up to 8 minutes) 4.7 1.8 1. When pressure falls. ORIFICE 0. once normal conditions have been re-established.7 0. the lower the line pressure and the greater the drop rate. the absolute pressure in the line and the pressure drop speed: the smaller the orifice. 35 Bar Pres. The time elapsed depends on the diameter of the calibrated orifice. The pressure switch acts upon the valve (Item 41) which permits the closing of the main valve.6 1.File linebreak GO LINE-BREAK TECHNICAL INFORMATION SECTION (E) . the bigger the volume of the rate tank and the lower the absolute pressure the greater the differential pressure (∆P) across the diaphragm valve.5 1. This orifice restrictor creates a differential pressure (∆P) that acts upon the adj.2 0.5 2.4 mm diameter calibrated orifice hole for the lower values of pressure drop speed at a high value of working pressure. When pressure starts to drop due to a pipeline break down. When pipeline pressure rises.5 1.75 2.75 3.75 0. As differential pressure needs to be limited within the selected range.25 1 0. pressure switch (40) if it exceeds the adjusted value.6 0. 65 Bar Pres. In order to open the main valve again.3 1. pressure switch valve can be adjusted within the range from 0.5 0. or the 0.25 2 1.3 The connection coming from the gasline can be intercepted using a stop valve (34) and the gas is filtered (37).25 3 2. 85 Bar FIGURE 1 The ∆P is obtained within the maximum time of 480 seconds for Natural Gas at 20 °C.5 0.9 Pressure Drop Speed ( Bar / min ) Pres. it is necessary to use the 0. 55 Bar Pres.75 1. for the higher value of pressure drop speed at low working pressure. the longer the time required to reach the maximum value of differential pressure. the ∆P takes time to reach its maximum value.

8 mm (Time from 1 up to 4 minutes ) 4.75 3. To change the calibrated orifice (36).25 0. The minimum working pressure has been chosen to prevent undesired line break interventions (in fact at this time the ∆P is higher than at maximum working pressure). 25 Bar Pres. . 65 Bar Pres.75 3 3.75 1. up to the desirable value. referring to the graded scale indicator.25 Pressure Drop Speed ( Bar / min ) FIGURE 2 The ∆P is obtained within the maximum time of 240 seconds for Natural Gas at 20 °C.5 2. ORIFICE 0.75 1 1.75 2.25 2 1.the variation range of working pressure. 85 Bar ∆P ( Bar ) for NATURAL GAS at 20 °C 3. To carry out the setting on the diaphragm valve.5 3.25 1 0.5 0. it necessary to know: .25 4 Pres. screw the replacing orifice tightly by means of a “8 mm” Allen key and screw back the cap screw tightly using the “17 mm” Allen key.File linebreak GO LINE-BREAK TECHNICAL INFORMATION SECTION (E) . CALIBRATION AND SETTING OF LINE-BREAK DEVICE: To carry out the setting and calibration of the Line-break device.8mm orifice.5 1.Par.5 mm” hexagonal screw and rotate the pommel nut on the top. first make sure that the system is depressurised.75 2 2.the pressure drop speed at minimum working pressure.25 3. 75 Bar Pres. 45 Bar Pres. From this intersection trace a horizontal line to the vertical axis and read the ∆P value.25 2.25 0 0 0. 55 Bar Pres. Use of Calibration charts (Figures 1 & 2) to find the correct orifice and the ∆P: find the specified drop rate along the horizontal axis and trace a line upward to where it intersects the specified minimum working pressure.5 0. 35 Bar Pres.75 4 4.5 2.25 3 2.5 1.75 0. remove the cover. unscrew the “5. Then remove the cap by means of “17 mm” Allen key and then the second screw inside the block by means of a “8 mm” Allen key. Ensure that all connections are leak tight and check with soapy water when the system is pressurized 24 . Now.5 3.3 FIGURE 2 Curves related to maximum ∆P acting upon the diaphragm valve at differential initial pressure and at differential pressure drop rate. with the 0.25 1.

. 1.S E C T Par.Maintenance I O N (F) 25 .

P7 P8 4B 4A P6 16 P5 26 . Proceed as follows: Place the actuator in the close position. a preventive approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. No inspection or repair should be undertaken unless it conforms with applicable hazardous area certification requirements. remote control. After maintenance has been performed and re-assembly completed. However. the actuator should be isolated from remote control signals and pneumatic/hydraulic power supply.Par. local control and manual override. Any personnel working with or on the equipment must be properly trained for the work they are performing and aware of their responsibilities relating to health and safety in the workplace. They can inhibit cooling and thus raise the temperature above the maximum allowable limit. Verify that the power fluid supply pressure value is within the required range. Remove build-up dust and dirt from all actuator surfaces. follow the inspection guidelines as outlined below: PERIODIC INSPECTION Ensure that the actuator operates the valve correctly within the required cycle time. Check pneumatic/hydraulic connections for leaks. adjustment or maintenance of the actuator and controls may. Inspect actuator paint work for damages to ensure continued corrosion protection. Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the certification. Improper operation. depending on the application. The system should then be relieved of any internal pressure prior to disassembly. Rotork Fluid System recommends to change hydraulic oil at 6-year or 20000-operations intervals.1 Rotork actuators are designed to work for long periods of time under severe conditions. release potentially explosive gases and / or dangerous liquids. particularly if the actuator is not operated frequently enough. paragraph 2.File MAINT_GO MAINTENANCE SECTION (F) . Close the isolation valves (16). Visually inspect the external components of the actuator for physical damage. Unscrew the plugs (P5 & P6) and discharge the oil from the cylinder.. use the drain valve to drain the gas. Operate with the valves (4A and 4B) so as to drain the gas from the circuit. If there is a storage tank in the circuit. Touch-up as required in accordance to applicable paint specification INSTRUCTIONS FOR CHANGING OIL IN THE TANKS AND IN THE HYDRAULIC CIRCUIT. Unscrew the plugs (P7 & P8) and discharge the oil from the tanks. Tighten pipe fittings as required. Rotork can provide actuator maintenance contracts tailored to meet each individual customer’s requirements. Before performing maintenance. Reassemble the plugs and fill the tanks in accordance with the instructions brought in this section.g. The actuator should be cycled several times with all the existing controls e.

Fill the tank (26. Place the 3-way hand operated valve (28A1) in the “remote” position.1 26. Screw the plugs (item P4). Always acting with the pump (28B2) take the actuator in the complete close position.2 The following instructions prescribe the procedure for filling the gas/oil tanks of the GO series actuator. Unscrew the drain plug (P2). with the respective dipstick. close the drain plug. The actuator is now ready to be assembled to the valve and connected to the gas supply line.File FILL_GO GAS / OIL TANKS OIL FILLING INSTRUCTIONS AND HYDRAULIC CIRCUIT PURGE SECTION (F) .1) with oil to the max level of the dipstick. P4 P3 26. Start pumping (28B1) until oil spills out from the hole of the drain plug (P1). Place the 3-way hand-operated valve (28A2) in the “remote” position and the valve (28A1) in the “manual” position. take the actuator in the completely open position.2) using dipstick. Using the pump (28B1) set the actuator in the completely open position. if necessary refill to max level. Always acting with the pump (28B1). Check the oil level in the tank (26.2 28B2 28B1 P2 P1 28A2 28A1 This operation should precede the assembling of the actuator on to the valve and the connecting of the gas supply line. close the drain plug.1) using a dipstick. Start pumping (28B2) until oil spills out from the hole of the drain plug (P2). Check the oil level in the tank (26. Unscrew and remove the plug (P4). Unscrew and remove the plug (P3). Place the 3-way hand operated valve (28A2) in the “manual” position.2) with oil to the max level of the dipstick. Place the 3-way hand operated valves (28A1) in the “remote” position. 27 . if necessary refill to max level. (if applicable). this setting can be checked through the position indicator displayed on the carter cover or on the microswitches box. Fill the tank (26. as described below: Actuators have been sent by Rotork Fluid System set in the close position. Unscrew the drain plug (P1). Screw the plugs (P3).Par. with the respective dipstick. Place the 3-way hand operated valve (28A1) in the “manual” position.

.Replacement of cylinder seals T I O N (G) 28 .S E C Par. 1.

.Unscrew the bolts (17). the sliding rings (9) and the gaskets (1 & 5). . . .File GO_SEAL REPLACEMENT OF CYLINDER SEALS (scotch yoke series) SECTION (G) .Par.Remove the cover (22). Make sure that the cylinder components are in a good condition and clean. proceed as described here below (See tables DSGA006 and DSGE119): This procedure is applicable after making sure that pneumatic/hydraulic pressure and electrical power have been removed from the actuator.Remove the o-rings (12 .Unscrew the piston rod (6) from the guide block (table A item 7) and slide it off. PHASE 1-DISASSEMBLY 1. PHASE 2-SEALS REPLACEMNT . due to a leakage or for scheduled preventive maintenance. .HYDRAULIC CYLINDER (See table DSGE119) .2 . . 21) the back-up rings (23 .1 When cylinder seals need to be replaced.Remove the end flange (13).Loosen the dowel (item 4).CENTER BODY (See table DSGA006) .Unscrew the nuts (17). .24). . HYDRAULIC CYLINDER (Table DSGE119) CENTER BODY (Table DSGA006) 29 .Disconnect the hydraulic supply tubes from the cylinder head and bottom flanges. Carefully clean the respective grooves.Remove the head flange (4).Unscrew the screws (2). screwing 2 screws in the appropriate thread holes on the cover to facilitate the removing operation.1 . the piston gasket (10). Replace all the above mentioned seals and lubricate them with a grease film. 1.Remove the cylinder tube (7).

File GO_SEAL REPLACEMENT OF CYLINDER SEALS (scotch yoke series) SECTION (G) . otherwise replace it. .Tighten the dowel (table A item 4). alternating between opposite corners.Par. .5 20 40 55 110 220 430 425 585 785 1250 1400 1750 FT.Screw the bolts ( 17) to the recommended torque (see table).CENTER BODY (See table A) .Reassemble the end flange (13).Reassemble the cover (22) using the parallel pin reference.1 PHASE 3 REASSEMBLY 3. alternating between opposite corners. LBS 6 15 30 40 81 162 317 313 431 579 921 1030 1290 30 .Tighten the nuts (17) to the recommended torque (see table).2 . RECOMMENDED TIGHTENING TORQUE Bolt size M6 M8 M10 M12 M14 M16 M20 M22 M24 M27 M30 M33 M36 NM 8. .If necessary. . .1 .Check if the cover gasket (13) is in a good condition. If necessary repaint them in accordance with the applicable painting specifications. 3.Reassemble the head flange (4) and screw the bolts (2) to the recommended torque (see table). . alternating between opposite corners.Carry out a few operations with the actuator in order to check if the movement is regular and if there are leakages through the seals. . . .Reassemble the cylinder tube (7). CENTER BODY (Table DSGA006) . Check if the painted parts have been damaged during the disassembly and reassembly.HYDRAULIC CYLINDER (See table DSGE119) HYDRAULIC CYLINDER (Table DSGE119) Taking care not to damage the seals proceed with the reassembling as follows: . reset the angular stroke in accordance with the instructions in section “C”.Reassemble the piston rod (6) by screwing it in onto the guide block (See table A item 7).Connect the oil supply tubes to the cylinder end and head flanges.

Tighten the screw (2) to the recommended torque (see table) alternating between opposite corners.Make sure that the cylinder components are in a good condition and clean.Carefully clean the relative grooves. .File GO_SEAL REPLACEMENT OF CYLINDER SEALS (rack and pinion series) SECTION (G) . Check if the painted parts have been damaged during disassembly and/or reassembly.Remove the piston gasket (8). .Disconnect the hydraulic supply tube from the cylinder.Unscrew the screw (2). . If necessary repaint them in accordance with the applicable painting specifications. Replace all the above mentioned seals and lubricate them with a grease film. . PHASE 3-REASSEMBLY Taking care not to damage the seals. PHASE 2-SEALS REPLACEMENT .2 PHASE 1-DISASSEMBLY HYDRAULIC CYLINDER (Table DSRE004) . . LBS 6 15 30 40 81 162 317 313 431 579 921 1030 1290 31 .Connect the hydraulic supply tube to the cylinder. the sliding rings (9) and the o-ring (11).Par. . .Carry out a few operations with the actuator in order to check if the movement is regular and if there are any leakages through the seals. .Reassemble the cylinder tube (10).5 20 40 55 110 220 430 425 585 785 1250 1400 1750 FT. RECOMMENDED TIGHTENING TORQUE Bolt size M6 M8 M10 M12 M14 M16 M20 M22 M24 M27 M30 M33 M36 NM 8.Remove the cylinder (10). proceed with the reassembling in the following way.

Hydraulic oil features I O N (H) 32 .Lubrication T Par. 1 .S E C Par. 2 .

refer to the type described in the Instructions Manual. there is no need to lubricate the actuator because its mechanism is lubricated-for life. 33 . In case a different grease type is requested. The following greases are used by Rotork Fluid System to lubricate the mechanical components and they are recommended for a possible lubrication: GREASE FOR GO SCOTCH YOKE SERIES MANUFACTURER: TRADE NAME: COLOR: SOAP TYPE: OIL TYPE: CONSISTENCY (NLGI GRADE)-ASTM D217: WORKED PENETRATION AT 25°C-ASTM D217: DROPPING POINT-ASTM D2265 VISCOSITY OF BASE OIL AT 40°C-ASTM D445: VISCOSITY OF BASE OIL AT 100°C-ASTM D445: MOBIL MOBILTEMP 78 GRAY/BLACK INORGANIC MINERAL 1 295/325 dmm 260°C 485 cSt 32 cSt GREASE FOR GO RACK AND PINION SERIES MANUFACTURER: TRADE NAME: COLOR: CONSISTENCY NLGI-ASTM D217: LITHIUM SOAP: DROPPING POINT-ASTM D566: BASE OIL FLASH POINT-ASTM D92: OIL SEPARATION-DIN 51817: OPERATING TEMPERATURE: TEXACO GREASE L00 DARK BROWN 00 6% 180°C 220°C 2% MAX -30°/+110°C Note: The above described grease types is the Rotork Fluid System standard for lubrication of scotch yoke and rack and pinion actuators.LUBRICATION File GREASE SECTION (H) .1 In general.Par.

5 cSt 4.2 MANUFACTURER: TRADE NAME: VISCOSITY AT 40°C: VISCOSITY AT 100°C: VISCOSITY INDEX ASTM: ISO GRADE: POUR POINT: SPECIFIC WEIGHT AT 15°C: MOBIL DTE 11 16. 34 . refer to the type described in the Instruction Manual.85 kg/dm3 Note: The above described oil type is the Rotork Fluid System standard.Par.File HYDROIL_03 HYDRAULIC OIL FEATURES SECTION (H) . In case a different oil type is requested.2 cSt 168 16 -42 °C 0.

Typical sectional drawings with parts-list I O N (I) 35 .S E C T Par. 1 .

36 .

37 .

38 .

39 .

40 .

41 .

1 .Instructions for actuator lifting I O N (L) 42 .S E C T Par.

43 .

S E C T Par. 2 – Features of the Rotork limit switch box type MB1 O N (M) 44 . 1 – Operating instructions for electric control systems I Par.

Par.1 In case the actuator is provided with an electric control system.OPERATING INSTRUCTIONS FOR ELECTRIC CONTROL SYSTEMS SECTION (M) . the setting is performed by Rotork Fluid System during actuator testing operations. For the start-up and should it be necessary to re-set the electric components. 45 . please proceed as described here below: WARNING • DO NOT OPEN ELECTRIC COMPONENTS UNDER VOLTAGE! • CHECK THE ELECTRIC EARTH BEFORE OPERATING ELECTRIC COMPONENTS! • REFER TO THE MANUFACTURER USER GUIDE FOR THE CORRECT USE OF ELECTRIC COMPONENTS.

Technical data Refer to the technical data on the rating plate on each control component or to the manufacture user guide. Assembling and maintenance staff therefore bear particular responsibility. manufactured and inspected in accordance with ISO 9001. Conversions and modifications to equipment which might impair explosion protection are not allowed. Conformity to standards Controls are state of the art. Safety guidelines contained herein. The equipment may be operated only if undamaged and clean. Test certificates and special conditions outlined in them. They have been developed. National accident prevention regulations.OPERATING INSTRUCTIONS FOR ELECTRIC CONTROL SYSTEMS SECTION (M) . the safety of the people and the plant depends on the adherence to all safety regulations. Installation and operation The following must be observed with regards to setting up and operating the explosion-proof equipment: • • • • National safety regulations National equipment safety legislation National installation regulations Generally recognized technical regulations This equipment may be transported and stored only in its original packaging. Safety instructions Observe the following during setting-up and operation: • • • • • National safety regulations. Characteristic values on the rating and data plates. The prerequisite is a thorough knowledge and understanding of the rules and regulations in place.1 Purpose of these instructions During work in explosive environments. These introductions give a brief summary of the most important safety measures and regulations to be observed by the staff. Damages neutralize explosion safety.Par. 46 .

250 V.c. 115 V.5 A 0.c.25 A 0.ROTORK LIMIT SWITCH BOX TYPE MB1 SECTION (M) . 250 V.c.5 SAK 2. MICROSWITCHES TYPE M2 K5 VCF V37YR 1HS3 BZ-2RW8227 2551-A2 Z 15GW22 VOLTAGE 250 V.03 A BURGESS 5A 10 A 25 A 10 A HONEYWELL 1A 1A 1A 0.c.a. RESISTIVE LOAD INDUCTIVE LOAD MANUFACTURER 0.5 MANUFACTURER WEIDMULLER WEIDMULLER WEIDMULLER WEIDMULLER WEIDMULLER WEIDMULLER IMPORTANT NOTICE: Before operating any of the above electric components. 250 V. 28 V.5 1.c.c.25 A 0.a.25 A BURGESS 25 A 15 A 0.c.25 A BURGESS 15 A 15 A 0.5 VOLTAGE 380 V 250 V 750 V 380 V 250 V 750 V NOMINAL CURRENT 25A 18A 26A 25A 18A 26A SECTION mm2 2.a. see section (M) . 125 V.5 2.c.5 A 0.c.25 A 15 A 1A 0. 250 V. 250 V.018 The ROTORK limit switch enclosure can contain electric limit switches and terminal boards where switches wires are connected according as required by the customer.a.5 2.2 FEATURES • • • • • • Electric protection EEx d IIC T6 Mechanical protection IP67 MAX voltage 250 V MAX current 25 A Nominal frequency 50/60 Hz Tested according to EN 50.c.a.5 2.c.03 A BURGESS 10 A 10 A 0. 250 V.Par.c.1 47 .Par. 250 V.c.5 1.c.5 SAK 2.c.a.c. The external cable connection to terminals is at user’s care.c. 250 V.a.5 MK3 AKZ 1.c. 250 V.014 and EN 50.c.25 A 15 A HONEYWELL OMRON TERMINALS TYPE MK3 AKZ 1.