LAB 5

FAKULTI TEKNOLOGI KEJURUTERAAN

MEKANIKAL DAN PEMBUATAN
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BMMM 3553 PENYELENGGARAAN MESIN MEKANIKAL

LAB SHEET 5

LAB 5: MAINTENANCE OF ACTUATORS

Learning LO2 Display maintenance techniques in mechanical components

Outcome (LO):
Program PO4 Ability to plan and conduct experimental investigations of broadly-
Outcome: defined problems, using data from relevant sources.
Synopsis: The RT 395 Trainer - Maintenance of Valves and Fittings and Actuators - facilitates
training on large and heavy industrial valves. The unit consists of a strong work bench
with a wooden work surface and a switch panel. The switch panel provides the student
with the necessary electrical and pneumatic setting options for testing and calibrating the
valves. In addition, it contains measuring instruments that display the pneumatic
pressures and electrical variables such as voltage and current. There is a vice on the
work bench for assembly work. The unit enables the student to connect various valves
and to understand their function and behaviour. The four valves to be studied are as
follows:
– Pneumatic butterfly valve
– Pneumatic ball valve
– Pneumatic control valve with electro-pneumatic positioner
– Pressure reducer To operate, the unit requires an electrical power supply and a
compressed air connection.

Related Lecture’s CHAPTER 5

Topic:
Prepared by: Azrin Bin Ahmad Date: 12/10/2022

Approved by Dr. Muhammad Ilman Hakimi Chua bin Date

LM/SLM/PP/HOD Abdullah

QMS : REVISION RECORDS

Revision Date Approved by

Description Prepared by :
No (DD/MM/YY) LM/SLM/HOD:

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1.0 THEORY

Pneumatic control valve with electro-pneumatic positioner.

Layout
The control valve consists of three main assemblies
- the actual valve body (bottom), the pneumatic
adjusting drive (top) and the electro-pneumatic A
positioner (below the adjusting drive). The
drive rod with position indicator can be seen
between the valve body and the adjusting drive.
The positioner includes a pressure gauge, which
displays the operating pressure.

Fig. 1.1 Pneumatic control valve with electro-

pneumatic positioner 0...20 mA
A - Connection for pneumatic auxiliary power

Function

Valve
3
The actual valve that controls the flow consists of
the housing (1) with valve seat (2) and the valve 4
cone (4) that moves by way of the plug stem (3).
2

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Electro-pneumatic positioner
The electro-pneumatic positioner is used for assignment of the valve position (control variable)
and the control signal (reference variable). The control signal coming from the regulating or control
system is compared with the stroke of the control valve and a pneumatic operating pressure (output
variable) is actuated. For this to function correctly, the positioner mode, the operating direction and
the calibration must be checked.

In the positioner, the I/P transducer (current pressure converter) converts the DC control signal
in the range 4...20 mA coming from the control device into a proportional pressure signal. This pressure signal
pe creates an adjusting force at a measuring diaphragm, which is compared with the force of a spring. The lever
transmits the movement of the measuring diaphragm to the double cone of the amplifier, so that a corresponding
operating pressure pst is initiated. The operating pressure pst is the reference variable that determines the flow
in the valve by way of the adjusting drive, the drive rod and the valve cone. The stroke can be read off on the
drive rod.

Pneumatic spherical segment valve with pneumatic drive

Layout
The pneumatic control valve consists of the spherical
segment valve and the pneumatic slewing
gear. The force is transmitted from the drive to the
spherical segment via a square or a feather key on
the valve shaft. The valve shaft is sealed by a floating
calliper stuffing box packing.

Function
The medium flows towards the convex side of the
sphere in the spherical segment valve. When the
valve is closed, the pressure acts on the convex Fig. 1.2 Spherical segment valve
side of the sphere. The characteristic flow value is
derived from the opening angle of the sphere. The control valve is used for both control and for
open/close operations in process technology and plant engineering.

The medium flows through the valve, with the operating pressure acting on the slewing gear influencing
the position (opening angle) of the spherical segment and thus the flow over the area released
between the spherical segment and the housing. The special feature of the valve is that the
design of the spherical segment means that each valve can optionally be used with two characteristic
curves (equal percentage/linear).
Valve

3
The area released for flow between the housing and the spherical segment varies depending on
the position (opening angle) of the spherical segment. Two different spherical segment contours
allow each valve to be used with two characteristic curves.
• “Equal percentage” (default)
To close the valve, the drive turns clockwise (to the right) when looking from the drive towards the
valve.
• “Linear”
To close the valve, the modified drive turns anticlockwise (to the left) when looking from the
drive towards the valve.

Adjusting mechanism
The adjusting mechanism is a single acting piston slewing gear. The safety position of the valve is
ensured by a spring.

2.0 EQUIPMENTS/ EXPERIMENT APPARATUS/ CONSUMABLE MATERIALS

1. Pneumatic control valve with electro-pneumatic positioner

2. Pneumatic spherical segment valve with pneumatic drive

3. RT 395 Gunt Hamburg Trainer

3.0 PROCEDURES/ METHODOLOGY

4
 A. Adjustment for "Actuator stem extends"

Note! To ensure that the entire closing force can be effective in the control valve, the diaphragm

chamber must be completely vented when reaching the Iower (operating direction >>) range value.

Fig 3.1 Nomenclature for adjustment of the clamp in electro-pneumatic positioner.

Starting point (zero)

e.g. 0.23 bar (4.5 mA)

1. Turn ZERO adjustment screw (fig 3.1) until the plug stem just begins to move from its resting

position (observe plug stem via travel indicator).

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 Travel
indicator

Fig 3.2 Travel indicator

2. Decrease input signal and increase again slowly. Check whether the plug stem starts moving at a starting
point of 0.23 bar (4.5 mA) and correct it, if necessary.

Upper range value (travel)

e.g. 1 bar (20 mA)

3. Alter the starting point has been adjusted, increase input signal. The plug stem must stand still at an upper
range value of exactly 1bar (20 mA). It must have passed through 100%travel (observe the travel indicator on
the valve!). If the upper range value does not correlate, correct it via SPAN adjustment screw (Fig 3.1).
Turning the screw towards the fulcrum of the lever increases the travel, whereas turning it away reduces the
travel.

Important!

The maximum supply pressure for actuators with fail-safe action “Actuator stem extends” and
mechanical travel stops should not exceed the upper spring range value by more than 1.5 bar.

4. Measure the outer length and inner length of the spring using the ruler when the starting point
(zero)

Inner
length Outer length

6
B. Functional test - Pneumatic control valve with electro-pneumatic positioner

1. Switch on master switch

2. Ensure compressed air supply is connected (8 bar). If not sure please ask the instructor

3. Attach a compressed air hose to the valve compressed air connection and then connect

to the compressed air output, e.g. at 1.5 bar.

4. Use the fine regulator valve and the pressure gauge to set the output pressure for the valve

auxiliary power 1.5 bar

5. Create the electrical connection between the positioner and the adjustable current source.

6. Connect a red signal lead to the red (+) socket and a blue signal lead to the blue (-) socket.

7. Press the arrow up and down for the adjustable current source to change the position of the valve
and then check the valve position.

Signal I out , mA Valve Position/ Indicator

12

20

ATTENTION! When dismantling the experiment, first of all reduce the pressure to 0 bar

and disconnect the compressed air line from the self-closing output on the switch panel.

ATTENTION! Do not connect the valve’s electrical connection leading to a 24 V supply.

7
 C. Exercises butterfly valve with actuator

Fig 3.3 Cross-sectional drawing actuator

Fig 3.4 Part list actuator

8
 Important safety Notice:

• The actuator must not be pressurized at any time during Installation as injury may result.

• The utmost cleanliness is required during air supply connection to the actuator i.e. the

connecting pipe thread, fittings and seals must be clean and dirt-free.

• When fitting accessories onto the actuator assemble them in such a way that the top of

the drive shaft is easily accessible should manual Operation of the actuator be

required.

• Before fitting onto the valve make sure that the actuator / valve are correctly orientated,

depending upon which direction of rotation is required

Disassembly and assembly of an actuator pls refer next page

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RT 395 MAINTENANCE OF VALVES AND FITTINGS AND ACTUATORS

2.1.2 Disassembly of an actuator

When disassembly of actuator is required for

maintenance, firstly remove the actuator from the
valve.
Caution!
Before performing any disassembly operations it is
important to verify that the actuator is not pressur-
ised. Always use caution and double check that
the ports "2" and "4" are vented and are free from
any accessory and / or device.
When the actuator is a spring return unit, make
sure that the actuator is in the failed position before
disassembling.

Removal of position indicator (19):

(Figure 2.7)
• Remove cap screw (24) if fitted
• Lift position indicator (19) off shaft, it may be
necessary to pry gently with a screwdriver.

Fig. 2.7 Removal of stop cap screws (2):

(Figure 2.8)
• Remove both stop cap screws (2) together
with. nut (4) and washer (3)
• Remove stop screw O-rings (11) and discard
if replacing all soft parts.

Fig. 2.8

28 2 Exercises butterfly valve with actuator

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RT 395 MAINTENANCE OF VALVES AND FITTINGS AND ACTUATORS

End Caps disassembly (22 and 23):

(Figure 2.9)
For model DAP/SRP 900 to DAP/SRP 3000 the
2 end caps (22) are symmetric.
• Remove cap screw (13) in the sequence
shown in the figure 2.9.
Caution!
When disassembling a spring return actuator, the
All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 03/2006

end cap (22 and 23) should be loose after

Fig. 2.9 unscrewing end cap bolts (13) 4-5 turns. If there is
still force an the end cap after 4-5 turns of the end
cap bolts, this may indicate a damaged spring
cartridge and any further disassembly should be
discontinued. Further disassembly of the end caps
may result in injury. Return actuator to Pfeiffer for
further maintenance.
• For spring return actuators, always remove
spring cartridge (17).
• Remove end cap O-rings (14) and discard if
replacing all soft components.

Pistons disassembly (25):

(Figure 2.10)
• Holding the body (29) in a vice or similar
device, rotate the drive shaft (30) until the
Fig. 2.10 pistons (25) are released.
Caution!
Air pressure should not be used to remove the
pistons from the body.
• Remove piston O-rings (16) using a small
screwdriver; remove the piston back (5) and
piston head (15) bearings. Discard bearings
when replacing all soft components.

2 Exercises butterfly valve with actuator 29

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RT 395 MAINTENANCE OF VALVES AND FITTINGS AND ACTUATORS

Pistons assembly (25):

(Figures 2.15, 2.16, 2.17, 2.18 and 2.19)
• Install piston O-rings (16), the Piston skirt (5)
and piston head (15) bearings.
• Grease the internal surface of the body (29)
and the piston (25) rack teeth.
• Hold the body (29) in a horizontal position by
Fig. 2.15 inserting the top of the shaft into a vice or the
bottom of the shaft connection into a male
drive fitted in a vice as shown in figure 2.15.
• Ensure that the octi-cam (1) is in the right
position as shown in figure 2.16.
• For standard rotation assembly (clockwise to
close) rotate the body (29) about 40° - 45°
counter-clockwise from bottom view or clock-
wise from top view depending an which way
the shaft has been linked as shown in figure
Fig. 2.16
2.17 and 2.18.
• Press the two pistons (25) simultaneously
inside the body (29) until the pistons are
engaged and rotate the body clockwise from
bottom view or counter clockwise from top
view until the stroke is completed.
• Ensure that when the pistons are inserted
that they both mesh at the same time. Check
fully closed and open positions as shown in
Fig. 2.17 figure 2.19.

Fig. 2.18 Fig. 2.19

32 2 Exercises butterfly valve with actuator

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RT 395 MAINTENANCE OF VALVES AND FITTINGS AND ACTUATORS

All Rights Reserved G.U.N.T. Gerätebau GmbH, Barsbüttel, Germany 03/2006

Fig. 2.20

End cap (22 right and 23 left)

and spring cartridge (17) assembly:
(Figures 2.20, 2.21 and 2.22)
For model DAP / SRP 2000 to DAP / SRP 3000 the
2 end caps (22) are symmetric

• Lubricate the body.

• For spring return actuator insert the proper
quantity of spring cartridge according to the
pattern shown in figure 2.20 (referring to the
total number of springs). Insert spring car-
tridge (17) as shown in figure 2.21.
Fig. 2.21 • Fit end cap O-ring seal (14) into the groove in
the end cap, an both end caps.
• Fit end caps onto the body (29), verifying that
the O-ring remains in the groove.
• Insert all the cap screws (13) and tighten
each only partially. Complete tightening by
following the sequence indicated in figure
2.22.

Fig. 2.22

2 Exercises butterfly valve with actuator 33

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RT 395 MAINTENANCE OF VALVES AND FITTINGS AND ACTUATORS

2.1.4 Stroke adjustment - actuator

Assembly of stop cap screws (2) and stroke adjust-

ment: (Figure 2.23)
• Insert on both the stop cap screw (2), the nut
(4), the washer (3), and the O-ring (11) in.
• Fit the stop cap screw (2) in the body.

Stroke adjustment for standard rotation actuator

(Clockwise to close):
Fig. 2.23 • 0° (Close) position stroke adjustment with
actuator in close position, screw or unscrew
the right (from top view) stop cap screw (2)
until the desired stop position is achieved.
Then tighten the stop adjustment nut (4) to
lock it in place.
• 90° (open) position stroke adjustment with
actuator in open position, screw or unscrew
the left (from top view) stop cap screw (2)
until the desired stop position is achieved,
then tighten the stop adjustment nut (4) and
lock it in place.

Assembly of position indicator (19 and 24):

(Figure 2.24)
• Fit position indicator (19) an the shaft verify-
ing that it indicates the correct actuator posi-
tion.
• Then fit cap screw (24) where fitted.

Fig. 2.24

34 2 Exercises butterfly valve with actuator

 D. Functional test - Butterfly valve with pneumatic drive

1. Switch on the master switch

2. Ensure the compressed air supply is connected (8 bar). If not sure please ask the instructor

3. Use the two fine regulator valves and the pressure gauge to set the output pressures (e.g. 1 bar / 5
bar)

4. Connect the compressed air connection on the butterfly valve to a compressed air line and then
connect the other end of the compressed air line to the switchable compressed air output marked
“½".

5. Use the changeover switch to test the function of the butterfly valve

Pressure , bar Valve Position

6. Observe at what pressure the Valve start to open and close and note the reading.

ATTENTION! When dismantling the experiment, first of all, reduce the

pressure to 0 bar and disconnect the compressed air line from the self-
closing output on the switch panel.

4.0 RESULTS

A. Adjustment for "Actuator stem extends"

1. The Inner and Outer Length of adjusted springs is

a. _______________________________________

b. _________________________________________

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B. Functional test - Pneumatic control valve with electro-pneumatic positioner

Signal I out , mA Valve Position/ Indicator

12

20

D. Functional test - Butterfly valve with pneumatic drive

1. Fill in the table below

Pressure , bar Valve Position

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5.0 DISCUSSION
Write a discussion based on the experiment and these questions.

1) Can you explain the basic operating principle of an actuator drive?

2) Do you think that routine maintenance is useful and necessary for the actuator drive? Give
reasons for your decision.

6.0 CONCLUSION

Write your conclusion of this experiment.

7.0 OTHERS
Reference

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ASSESSMENT CRITERIA:

Your response to each task will be graded separately based on the checklist attached. To obtain
maximum marks, ensure that your response addresses each of the tasks in the question accordingly.

Assessment checklist for Lab Activity 1

Assessment tasks Mark LO PO C/P/A level

allocation

Procedure: Reproduce Bill of 16 LO2 PO4

Material List for sub-assembly unit P4-Mechanism
and create assembly process

Discussion: LO2 PO4 P5 –Complex

Overt Response
1) Plan a maintenance order 8
2) Test recording 6
3) Trends/patterns are clearly 4
analysed
4) Analysis is insightful and 8
discussed according to theory;
good understanding of results is
conveyed.

Conclusion 8 LO2 PO4 P5 –Complex

Overt Response
1) Relatable to discussion and results.

2) All-important conclusions have

been clearly made; student
shows good understanding.

TOTAL 50

SPECIFIC INSTRUCTION

1. Answer in ENGLISH .
2. Must include list of references .
3. Submit your assignment ONCE only in a SINGLE file.
4. Submit your assignment ONLINE.
5. Submission date: Week …..
6. This lab report/activity accounts for 5% of the total marks for the course.
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