sc/v - valve actuator spring return

sc/v - valve actuator spring return
SC/V - VALVE ACTUATOR
SPRING RETURN
INSTRUCTION MANUAL 5018
STI S.r.l has taken every care in collecting and verifying the documentation contained in this Instruction
Manual. The information herein contained are reserved property of STI S.r.l.
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www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
i
INDEX
1
GENERAL INFORMATION .................................................................................................................. 1
1.1
1.2
1.3
1.4
1.5
1.6
GENERALITIES .................................................................................................................................. 1
MANUFACTURER............................................................................................................................... 1
TERMS AND CONDITIONS ................................................................................................................... 1
MANUFACTURER’S LIABILITY .............................................................................................................. 1
APPLICABLE STANDARDS AND DIRECTIVES ........................................................................................ 2
SYMBOLOGY USED............................................................................................................................ 2
2
DEVICE DESCRIPTION ....................................................................................................................... 3
3
TECHNICAL DATA ............................................................................................................................... 4
4
LABEL ................................................................................................................................................... 5
5
OPERATING CONDITIONS AND INTENDED USE ............................................................................. 6
5.1
5.2
OPERATING CONDITIONS ................................................................................................................... 6
INTENDED USE .................................................................................................................................. 6
6
TRANSPORT ........................................................................................................................................ 7
7
RECEPTION.......................................................................................................................................... 7
8
STORAGE ............................................................................................................................................. 7
9
INSTALLATION .................................................................................................................................... 8
9.1
9.2
9.3
9.4
10
10.1
10.2
11
11.1
11.2
11.3
12
12.1
12.2
12.3
12.4
CHECKS TO BE PERFORMED BEFORE INSTALLATION ............................................................................ 8
ALIGNMENT OF THE SC/V VALVE ACTUATOR....................................................................................... 8
PNEUMATIC CONNECTIONS ................................................................................................................ 9
EARTHING CONNECTION .................................................................................................................... 9
INSTRUCTION FOR THE OPERATORS ....................................................................................... 10
FIELD ACTIVITIES ............................................................................................................................ 10
RESIDUAL RISKS ............................................................................................................................ 10
MAINTENANCE .............................................................................................................................. 11
PERIODIC INSPECTIONS AND MAINTENANCE...................................................................................... 11
EXTRAORDINARY MAINTENANCE ...................................................................................................... 11
GREASES ....................................................................................................................................... 12
PARTS LIST GENERAL ASSEMBLY ............................................................................................ 13
STEM EXTENDED + CASTING ACTUATOR.......................................................................................... 13
STEM EXTENDED + NO CASTING ACTUATOR .................................................................................... 17
STEM RETRACTED + CASTING ACTUATOR........................................................................................ 23
STEM RETRACTED + NO CASTING ACTUATOR .................................................................................. 27
13
TROUBLESHOOTING .................................................................................................................... 32
14
SPARE PARTS ............................................................................................................................... 32
15
DISASSEMBLING ........................................................................................................................... 33
16
DECOMMISSIONING ...................................................................................................................... 33
ANNEX A_SC/V200-320: STEM EXT. + CASTING CYL. ......................................................................... A1
ANNEX B_SC/V200-320: STEM RETR. + CASTING CYL. ...................................................................... B1
ANNEX C_SC/V200-320 RV: STEM RETR. + CASTING CYL. ................................................................ C1
ANNEX D_SC/V300-400-500-520: STEM EXT. + NO CASTING CYL. .................................................... D1
ANNEX E_SC/V300-400-500-520: STEM RETR. + NO CASTING CYL. ................................................. E1
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ii
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Manual 5018, rev. 01 06/2017 – SC/V
iii
1 GENERAL INFORMATION
Important
This Instruction Manual is an integral part of the machine, it should be carefully
read before carrying out any operation and it should be kept for future
references. The operators shall adopt the safety precautions required by the
country where the product is installed.
This Instruction Manual is realized in accordance with the Directive 2006/42/CE.
1.1 Generalities
STI S.r.l. actuators are conceived, manufactured and controlled according to the Quality management
System in compliance with EN ISO 9001 International Standard.
1.2 Manufacturer
With respect to Machinery Directive 2006/42/EC, the Manufacturer of the described SC/V valve actuator is
STI S.r.l. as specified on the label.
STI S.r.l. Via Dei Caravaggi 15
24040 Levate (BG) Italy
Tel. +39 035 2928.2
Fax +39 035 2928.247
imisti.sales@imi-critical.com
1.3 Terms and conditions
STI S.r.l. guarantees each single product to be free from defects and to conform to current goods
specifications. The warranty period is two years from the date of shipment to the first user. The warranty
does not cover special products or components not covered by warranty in their turn by subcontractors. No
warranty is given for products which have been subject to improper storage, improper installation, improper
maintenance or which have been modified or repaired by unauthorised personnel.
1.4 Manufacturer’s liability
The SC/V valve actuator is designed in accordance with the applicable International Rules and
Specifications, but the following regulations must be observed in any case:
the general and safety regulations;
the plant specific regulations and requirements;
the proper use of personal devices, protective devices (glasses, clothing, gloves, etc), tools and
transport equipment.
STI S.r.l. declines all liability in the event of:
use SC/V valve actuator in other applications than the designated ones;
use of the SC/V valve actuator in contravention of local safety at work legislation;
lack of care during transport, installation, operations, maintenances of the SC/V valve actuator or
incorrect application of the instructions provided on the SC/V valve actuator label and in this manual;
modifications or repairs without STI S.r.l. authorisation;
work done on the unit by unqualified or unsuitable operators.
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1
Considering that STI S.r.l. has no direct control over particular applications, operation or maintenance
conditions, it is the operator’s responsibility to comply with all applicable safety rules; it is the sole
responsibility of the operator to ensure that the local health and safety regulations are adhered to.
Depending on the specific working conditions, additional precautions may be requested.
Please inform STI S.r.l. urgently if you face unsafe situations not described in this Instruction Manual.
1.5 Applicable Standards and Directives
EN ISO 12100:2010
2006/42/EC
Safety of machinery - General principles for design - Risk assessment and risk
reduction
Functional safety of electrical / electronic / programmable electronic safetyrelated systems
Machinery Directive
97/23/EC
Pressure Equipments Directive (PED)
94/9/CE
Equipments used in potentially explosive atmospheres (ATEX)
IEC 61508:2010
1.6 Symbology used
Dangerous symbols: be careful where these symbols are shown, they indicate a potentially hazardous
situation and they warn that if the steps are not properly performed, may result causing serious injury,
death or long-term risks to the health of exposed persons.
GENERAL DANGER
DANGER POWER SUPPLY
CRUSHING HAZARD
Obligation symbols: if these symbols are shown, the corresponding direction shall be followed.
General obligation
(with the possible
supplementary
signboard)
Must wear
protective
clothing.
Must wear
protective
footwear.
Must wear
protective
helmet.
Must wear
protective
glasses
Must wear
earplugs
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2
2 DEVICE DESCRIPTION
The SC/V valve actuator is made by four main parts:
the cylinder group, with a piston inside that divides the internal volume in two chambers. A first stem
(actuator stem) connects the piston to the valve stem. Another stem connects the piston to the
spring/springs;
the spring group, collocated on the top of the cylinder;
the yoke, that fix the cylinder to the valve;
the manual override (not always required).
Different kind of pneumatic accessories could be mounting on the SC/V valve actuator depending on the
performance required.
There are four type of SC/V valve actuator Spring Return:
Single Acting Stem Extended, where the spring extend the actuator stem;
Single Acting Stem Retracted, where the spring retract the actuator stem;
Double Acting Stem Extended, where the spring extend the actuator stem;
Double Acting Stem Retracted, where the spring retract the actuator stem.
Figure 1 – SC/V valve actuator
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3
3 TECHNICAL DATA
Double/Single Acting Stem Extended (****)
Model
Cylinder material
Size (cylinder diameter)
/ Stroke (*)
Standard design
pressure (**)
Standard operating
temperature range (***)
Expected lifetime
Casting Cylinder
No Casting Cylinder
Aluminum
150mm/≤40mm
200mm/≤150mm
250mm/≤150mm
320mm/≤300mm
Carbon steel, Stainless steel, Fiber
200mm, 260mm, 300mm, 330mm,
390mm, 400mm, 420mm, 500mm,
520mm, 600mm, 635mm, 650mm,
735mm, 835mm, 850mm
10bar (*****)
10bar (*****)
-20°C/+70°C
-20°C/+70°C
20 years
20 years
Double/Single Acting Stem Retracted (****)
Model
Cylinder material
Size (cylinder diameter)
/ Stroke (*)
Standard design
pressure (**)
Standard operating
temperature range (***)
Expected lifetime
Casting Cylinder
No Casting Cylinder
Aluminum
150mm/≤40mm
200mm/≤153mm
250mm/≤153mm
320mm/≤305mm
Carbon steel, Stainless steel, Fiber
200mm, 260mm, 300mm, 330mm,
390mm, 400mm, 420mm, 500mm,
520mm, 600mm, 635mm, 650mm,
735mm, 835mm, 850mm
10bar (*****)
10bar (*****)
-20°C/+70°C
-20°C/+70°C
20 years
20 years
(*) Stroke for No Casting Actuators not defined in this table.
(**) For some special application the design pressure is 12 bar.
(***) For some special application the operating temperature range could be another one included in the
extended temperature range from -60°C to 100°C.
(****) Double and single acting actuators have the same design with the difference that in the first case both
the cylinder chambers are connected to the pneumatic supply line.
2
2
(*****) For double acting actuators: Air_Thrust [N] + Spring_Thrust [N] ≤ 0.1 * 10 [bar] * Size [mm ] * / 4.
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4
4 LABEL
Every SC/V valve actuator is provided with a label contains the main operating conditions and serial
number. The label may change if the SC/V valve actuator is sold with reference to a Certificate of product
and/or system issued by Notified Body Exterior or Certificate of Conformity issued by STI S.r.l..
Figure 2 – SC/V standard label
Warning
It is severely forbidden to use the SC/V valve actuator under conditions other than
those provided on the label.
Important
It is forbidden to modify the information and the marks without previous written
authorization by STI S.r.l..
Do not remove the label and/or replace with other label.
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5
5 OPERATING CONDITIONS AND INTENDED USE
Warning
It is severely forbidden to use the SC/V valve actuator for purpose or application
other than those for which it was designed and here specified.
5.1 Operating conditions
The label fastened on the SC/V valve actuator contains the main operating conditions for the specified
application (see Section 4). Other operating conditions are reported on the documents accompanying the
actuator. For general operating conditions see Section 3.
5.2 Intended use
The SC/V valve actuator series has been specifically designed for control valves, typically used in on-off
application or regulation mode. In order to open/close the valve without the support of the supply fluid, in
some application the manual override is required. Every manual override is provided with a label contains
the correct using steps.
Figure 3 – Manual override standard label
After the manual override using, take off the manual override pin and then check the correct behavior of the
SC/V valve actuator with a functional test or a visual check of the pin.
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6
6 TRANSPORT
Warning
The following instructions must be respected:
- operations must be carried out only by skilled operators;
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
Important
The lifting and handling should be made in compliance with the laws and
provisions in force.
Lift the SC/V valve actuator with belts, using its eyebolts. Make sure that the belts never scratches the
accessories and pneumatic/electric connection.
7 RECEPTION
SC/V valve actuator leave the factory in perfect condition. Performances of each unit are guaranteed by
tests and data reported on a specific Test Report. At the reception of the SC/V valve actuator:
check that the model correspond with that of order confirmation;
check that the pneumatic diagrams, wiring diagrams and dimensional drawing are furnished with
document accompanying the actuator;
check that the SC/V valve actuator was not damaged during transportation. If necessary renovate the
painting according to the specification reported on the order confirmation.
8 STORAGE
In order to maintain the guaranteed actuator performances until the SC/V valve actuator is installed on site,
proper attention must be observed for preservation during the storage period. If the SC/V valve actuator
needs storage before installation:
place it in a dry, clean place and take all necessary measures to avoid contact with dust, dirt and
humidity during storage;
make sure that connection protections and/or the mechanical locks will not be removed during the
storage;
storage temperature must be between -20°C and +40°C.
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7
9 INSTALLATION
Warning
The following instructions must be respected:
- operations must be carried out only by skilled operators;
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
Important
Not performing the following procedures will invalidate the product warranty.
9.1 Checks to be performed before installation
It is recommended to check the SC/V valve actuator conditions before the installation, then:
prepare the necessary tools for the assembly and setting of the unit;
check that the coupling dimensions meet the specified coupling dimensions;
clean the SC/V valve actuator surfaces and remove anything that might prevent a perfect adherence
with the valve;
9.2 Alignment of the SC/V valve actuator
After installation on the valve:
check that the SC/V valve actuator are correctly mounted on the valve and the actuator is perfectly
aligned with the valve stem;
make sure that there is no abnormal binding, sticking or jumping in the motion of the system
(actuator/applied load) for the whole shaft;
Warning
Do not lift the valve with the SC/V valve
actuator eyebolts
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9.3 Pneumatic connections
Warning
Check that the values of pneumatic supply available are compatible with those
reported on the label of the SC/V valve actuator: a pressure regulator is absolutely
necessary when supply pressure is higher than max operating pressure.
User must consider and take all precautions to avoid that pressurized parts are
not used out of specified range and to avoid exposure to fire.
Important
For easier maintenance, it is recommended to install a filter with five micron
cartridge and shut-off valve on the supply connection.
It is required to follow this steps during the pneumatic connection:
no lubricators on supply fluid line is required;
use pipes and connections appropriate as for type, rating, material and dimensions;
properly deburr the ends of rigid pipes;
properly clean the interior of pipes sending through them plenty of the supply fluid;
use pipe sealant sparingly and only on male threads. A non-hardening sealant is strongly
recommended;
fasten the connection pipes so that no irregular strains or loosening of threaded connections occur;
make the pneumatic connections according to the pneumatic diagram;
check the absence of leakages from pneumatic connections. If necessary tighten the nuts of the pipefittings;
after connecting the actuator, gradually increase the supply pressure up to the maximum operating
pressure.
9.4 Earthing connection
Warning
Check if the SC/V valve actuator has a properly earthing connection.
The earthing connection is guaranteed trough the fixing flange of the SC/V valve actuator. If the earthing
connection of the system where SC/V valve actuator is mounted is not guaranteed, it is required to ensure
a directly earthing connection.
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9
10 INSTRUCTION FOR THE OPERATORS
Warning
The following instructions must be respected:
- operations must be carried out only by skilled operators;
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
Important
Any repair work other than the operations outlines in this Instruction Manual is
allowed only if STI S.r.l. authorises it.
10.1 Field activities
During the start-up of the SC/V valve actuator:
- check that the pressure and quality of the supply fluid (filtering degree, dehydration, etcetera) are as
prescribed;
- check if the operating condition are as prescribed;
- check if the actuator is perfectly aligned with the valve stem;
- check that there are no leak of the pneumatic connections;
- check that there are no leak of the accessories mounted on the SC/V valve actuator;
- check that there are no leak of the cylinder of SC/V valve actuator;
- remove all rust on the SC/V valve actuator surfaces;
- repair paint-coat that has been damaged, in accordance with the applicable painting specifications;
- perform a complete functional test.
10.2 Residual Risks
Reasonably foreseeable misuse:
risk due to movements of loads during transport and installation;
crushing during transport and installation;
installation in ambient with not planned conditions;
metal temperature at high or very low values as consequence of ambient temperature as to be
considered as a risk of person injury in case of contact;
insert incorrect motive fluid into the system;
supply pressure out of planned range;
emissions of hazardous substances where dangerous gases are used as motive fluid.
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11 MAINTENANCE
Warning
The following instructions must be respected:
- operations must be carried out only by skilled operators (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
Before any type of operation and/or maintenance is performed, make sure that:
actuator, accessories and all connected equipment are not under pressure and in safe conditions;
fluid supply, power or other energy sources and signals are disconnected;
actuator is free from any mechanism able to move.
11.1 Periodic Inspections and maintenance
Periodic visual inspections are recommended. The user shall:
plan and provide for a periodic cleaning/maintenance program that will maintain the external surface of
the SC/V valve actuator free from excessive layer of dust;
lubrication the external mechanical devices in motion every six months (see Section 12.3 for the
correct grease type);
check painting status of the entire actuator at least every three months. If any damage on the painting
film is present, the user shall immediately carry out an adequate painting touch-up;
replace the gaskets and the grease every 2- 3 years depending on the actuator operating conditions;
see enclosed annexes for any details:
o 200-320 Stem Extended – Casting Cylinder;
o 200-320 Stem Retracted – Casting Cylinder;
o 200-320 RV Stem Retracted – Casting Cylinder;
o 300-400-500-520 Stem Extended – No Casting Cylinder;
o 300-400-500-520 Stem Retracted – No Casting Cylinder.
11.2 Extraordinary maintenance
In case of extraordinary maintenance, following malfunction and related troubleshooting, proceed as written
in Section 13.
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11
11.3 Greases
RHEOLUBE 361F
(Tecnolube seal)
Low
temperature
(-40°C< Tmin <20°C)
RHOESIL 500F
(Tecnolube seal)
Standard
temperature
(-20°C ≤ T ≤ 70°C)
MOLYGUARD
IDROSFER
SYNTHY 101
(Tecnolube seal)
Nickel plated
carbon steel
RHEOLUBE 361F
(Tecnolube seal)
RHOESIL 500F
(Tecnolube seal)
MOLYGUARD
IDROSFER
SYNTHY 101
(Tecnolube seal)
Chrome plated
carbon steel
RHEOLUBE 361F
(Tecnolube seal)
RHOESIL 500F
(Tecnolube seal)
POLIMER 400/1
(Tecnolube seal)
SYNTHY 101
(Tecnolube seal)
Stainless steel
RHEOLUBE 361F
(Tecnolube seal)
RHOESIL 500F
(Tecnolube seal)
POLIMER 400/1
(Tecnolube seal)
SYNTHY 101
(Tecnolube seal)
Fiber
RHEOLUBE 361F
(Tecnolube seal)
RHOESIL 500F
(Tecnolube seal)
POLIMER 400/1
(Tecnolube seal)
SYNTHY 101
(Tecnolube seal)
Manual
override
material
Very Low
temperature
(Tmin ≤-40°C)
Low
temperature
(-40°C<Tmin<-20°C)
Standard
temperature
High
temperature
(Tmax > 70°C)
All material
MOLIKOTE
MU EP
(Agip)
MU EP
(Agip)
MU EP
(Agip)
SC/V cylinder
material
Very Low
temperature
(Tmin ≤ -40°C)
Aluminum
High
temperature
(Tmax > 70°C)
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12
12 PARTS LIST GENERAL ASSEMBLY
12.1 Stem Extended + Casting Actuator
Figure 4 – Stem Extended Casting Actuator: typical design
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Figure 5 – Stem Extended Casting Actuator: option A
Figure 6 – Stem Extended Casting Actuator: option B
Figure 7 – Stem Extended Casting Actuator: option C
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Figure 8 – Stem Extended Casting Actuator: option D
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Figure 9 – Stem Extended Casting Actuator: option E
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12.2 Stem Extended + No Casting Actuator
Figure 10 – Stem Extended No Casting Actuator: typical design
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Figure 11 – Stem Extended No Casting Actuator: option A
Figure 12 – Stem Extended No Casting Actuator: option B
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Figure 13 – Stem Extended No Casting Actuator: option C
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Figure 14 – Stem Extended No Casting Actuator: option D
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Figure 15 – Stem Extended No Casting Actuator: option E
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Figure 16 – Stem Extended No Casting Actuator: option F
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12.3 Stem Retracted + Casting Actuator
Figure 17 – Stem Retracted Casting Actuator: typical design 1
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Figure 18 – Stem Retracted Casting Actuator: typical design 2
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Figure 19 – Stem Retracted Casting Actuator: option A
Figure 20 – Stem Retracted Casting Actuator: option B
Figure 21 – Stem Retracted Casting Actuator: option C
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Figure 22 – Stem Retracted Casting Actuator: option D
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12.4 Stem Retracted + No Casting Actuator
Figure 23 – Stem Retracted No Casting Actuator: typical design
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Figure 24 – Stem Retracted No Casting Actuator: option A
Figure 25 – Stem Retracted No Casting Actuator: option B
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STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
28
Figure 26 – Stem Retracted No Casting Actuator: option C
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
29
Figure 27 – Stem Retracted No Casting Actuator: option D
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
30
Figure 28 – Stem Retracted No Casting Actuator: option E
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
31
13 TROUBLESHOOTING
EVENT
POSSIBLE CAUSE
SC/V valve actuator
doesn’t move
Lack of pneumatic supply
Low supply pressure
Pneumatic circuit failure
Thrust on stem not enough (valve
seizing)
Thrust on stem not enough (wrong
actuator sizing)
Presence of an external obstruction
Damaged actuator internal component
Lubricators unsuitable
SC/V valve actuator
doesn’t move in a
linear way
Opening/Closing
time not satisfy
Stem misalignment
Thrust on stem not enough (valve
seizing)
Thrust on stem not enough (wrong
actuator sizing)
Incorrect positioner calibration
Pneumatic circuit not suitable
Wrong actuator sizing
Wrong spring selection
Spring vent clopping (if any)
Deterioration and/or damage of gasket
Leakages from
pneumatic cylinder
Leakages from
pneumatic circuit
Deterioration and/or damage of the
cylinder or the upper/lower cap
Incorrect tie rods tighten
The nuts of pipe fittings are not tighten
enough
An accessory does not work correctly
REMEDY
Check supply line
Adjust supply pressure
Call STI S.r.l.
Call valve manufacturer
Call STI S.r.l.
Put the SC/V valve actuator in a
safety condition and remove the
obstruction
Call STI S.r.l.
Replace the lubricators
Call STI S.r.l.
Check the actuator stem alignment
Call STI S.r.l.
Call valve manufacturer
Call STI S.r.l.
Call STI S.r.l.
Call STI S.r.l.
Call STI S.r.l.
Call STI S.r.l.
Check the spring vent
Replace the gaskets
Call STI S.r.l.
Call STI S.r.l.
Call STI S.r.l.
Tighten the nuts
Call STI S.r.l.
Important
If another event happens or another possible cause of the above events has
been detected, call STI S.r.l.
14 SPARE PARTS
Contact STI S.r.l. for the gasket kit required for the gaskets replacement. Other spare parts can be sent to
the customer if required.
_____________________________________________________________________________________
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Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
32
15 DISASSEMBLING
Important
The customer can disassemble the SC/V valve actuator only for the
gaskets/grease replacement (see Section 11).
In other cases, the disassembling is not allowed if it is not authorized by STI.
16 DECOMMISSIONING
Warning
The following instructions must be respected:
- operations must be carried out only by skilled operators;
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
Important
Check local authority regulation before disposal.
SUBJECT
HAZARDOUS
RECYCABLE
DISPOSAL
Metals
No
Yes
Use licensed recyclers
Plastics
No
Yes
Use specialist recyclers
Rubber (seals, o-rings)
Yes
No
May require special treatment
before disposal, use specialist
waste disposal companies
Oil and grease
Yes
Yes
May require special treatment
before disposal, use specialist
waste disposal companies
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
33
ANNEX A_SC/V200-320: Stem Ext. + Casting Cyl.
GASKETS REPLACEMENT
SC/V 200-320: Stem Extended + Casting Cylinder
Warning
The following instructions must be respected:
- operations must be carried out only by qualified staff (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
During the gaskets replacement:
take care to not damage gaskets grooves during maintenance;
use only the grease type shown in the enclosed table.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
Manual 5018, rev. 01 06/2017 – SC/V
www.imi-critical.com
A1
Disassembling:
9.1 Disconnect the actuator from the air supply and ensure the actuator is not pressurized.
9.2 Disconnect the actuator stem from the valve stem.
9.3 Disassemble the spring protection upper cover (pos.25) by unscrewing the tie rods and removing all
the accessories/fittings where needed.
Warning
Pay attention at the spring action.
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
Remove the spring protection cylinder (pos.13).
Remove the spring (pos.24).
While holding the stem (pos.10) unscrew the ring nut (pos.20).
Remove the spring guide and register (pos.17/21/22) and the bearing (pos.16).
Remove the upper cover of the actuator (pos.9) by unscrewing the screws.
Pull the piston (pos.2) and the piston (pos.15/10) from the cylinder (pos.1).
Remove the o-ring (pos. 33) from the cylinder
Remove sliding ring (pos.31) and o-ring (pos.32) from the piston.
Remove snap ring (pos.3), and push the bushing (pos.5) towards the inside of the actuator and
remove the gaskets (pos.6,7 and 8).
9.13 Repeat the same procedure as 9.12 for upper cover bushing (pos.9).
Replacement:
9.14 Clean the actuator parts with a mild detergent suitable for grease removal using a brush, then dry
with a cloth and compressed air.
9.15 Apply grease on the rough parts of back cylinder. Do not apply grease on the machined surfaces.
9.16 Apply grease to the o-ring and install them on the bushings. Insert and fix the bushings into the cover
and cylinder.
9.17 Fill the grease reservoir along the outer rim of the piston.
Important
Apply grease to the gaskets prior installation.
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
Install new gaskets kit.
Apply grease to the inside surface of the cylinder.
Install the sliding ring on the piston.
Install the o-ring on the piston and remove the excess grease.
Insert the piston into the actuator cylinder. Take care of the mounting direction.
Mount the upper cover on the actuator, torque the screws to the values indicated on the table below.
Install the spring guide components (pos.17/21/22) with the bearing (pos.16) and spacers
(pos.18/19), tighten the ring nut (pos.20).
Install the spring (pos.24) on the guide.
Install the protection cylinder (pos.13) and cover (pos.25), tighten the tie rods.
Test the piston movement using an air gun.
Plumb all pneumatic connections and check for air leaks at 1 bar (0,1 MPa) air supply pressure. If
there are no leaks, repeat the test at 7 bar (0,7 MPa).
Clean the excess grease from the shaft.
SC/V
Torque [Nm]
200
14 ( 10,3 lbf-ft )
320
20 ( 14,7 lbf-ft )
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
A2
ANNEX B_SC/V200-320: Stem Retr. + Casting Cyl.
GASKETS REPLACEMENT
SC/V 200-320: Stem Retracted + Casting Cylinder
Warning
The following instructions must be respected:
- operations must be carried out only by qualified staff (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
During the gaskets replacement:
take care to not damage gaskets grooves during maintenance;
use only the grease type shown in the enclosed table.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
B1
Disassembling:
9.1 Disconnect the actuator from the air supply and ensure the actuator is not pressurized.
9.2 Disconnect the actuator stem from the valve stem.
9.3 Disassemble the spring protection upper cover (pos.30) by unscrewing the nuts (pos.32) and
removing all the accessories/fittings where needed.
9.4 Remove the spring protection cylinder (pos.28).
9.5 Mark with a pen the internal screwed shaft (pos.21/22) position with the screw (pos.15).
9.6 Prevent the shaft (pos.15) from rotating while removing the spring preloader (pos.21/22).
9.7 Remove the spring register (pos.18) and the spring (pos.17).
9.8 Remove the upper cover of the actuator (pos.16) by removing the screws (pos.34).
9.9 Pull the shaft (pos.3) and the piston (pos.2) out from the cylinder (pos.1).
9.10 Take the o-ring (pos. 13) off of the cylinder.
9.11 Remove the sliding ring (pos.5) and o-ring (pos.6) from the piston.
9.12 Remove the snap ring (pos.8), push the bushing (pos.9) towards the inside of the actuator and
remove the gaskets (pos.10,11 and 12) away.
9.13 Repeat the same procedure as 9.12 for upper cover bushing.
Replacement:
9.14 Clean the actuator parts with a mild detergent suitable for grease removal using a brush, then dry
with a cloth and compressed air.
9.15 Apply grease on the rough parts of back cylinder. Do not apply grease on the machined surfaces.
9.16 Apply grease to the o-ring and install them on the bushings. Insert and fix the bushings into the cover
and cylinder.
9.17 Fill the grease reservoir along the outer rim of the piston.
Important
Apply grease to the gaskets prior installation.
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
Install new gaskets kit.
Apply grease to the inside surface of the cylinder.
Install the sliding ring on the piston.
Install the o-ring on the piston and remove the excess grease.
Insert the piston into the actuator cylinder. Take care of the mounting direction.
Mount the upper cover on the actuator, torque the screws to the values indicated on the table below.
Locking the screw (pos.21/22) to the internal screwed shaft (pos.15) to the previous position marked
with the pen.
Install the spring (pos.17) and the spring register (pos.18).
Install the protection cylinder (pos.28) and the cover (pos.30), tighten the nuts (pos.32).
Test the piston movement using an air gun.
Plumb all pneumatic connections and check for air leaks at 1 bar (0,1 MPa) air supply pressure. If
there are no leaks, repeat the test at 7 bar (0,7 MPa).
Clean the excess grease from the shaft.
SC/V
Torque [Nm]
200
320
14 ( 10,3 lbf-ft )
20 ( 14,7 lbf-ft )
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
B2
ANNEX C_SC/V200-320 RV: Stem Retr. + Casting Cyl.
GASKETS REPLACEMENT
SC/V 200-320 RV: Stem Retracted + Casting Cylinder
Warning
The following instructions must be respected:
- operations must be carried out only by qualified staff (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
During the gaskets replacement:
take care to not damage gaskets grooves during maintenance;
use only the grease type shown in the enclosed table.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
C1
Disassembling:
9.1
Disconnect the actuator from the air supply and ensure the actuator is not pressurized.
9.2
Disconnect the actuator stem from the valve stem
9.3
Remove the manual override handwheel (pos.33) and disassemble the spring protection upper
cover (pos.18) by unscrewing the nuts (pos.26) and removing all the accessories/fittings where
needed.
9.4
Remove the spring protection cylinder (pos.35).
9.5
Mark with a pen the internal screwed shaft (pos.31) position with the screw (pos.17).
9.6
Prevent the shaft (pos.31) from rotating while removing the spring preloader (pos.17).
9.7
Remove the spring register plate (pos.37) and spring (pos. 34).
9.8
Remove the upper cover of the actuator (pos.13) by removing the screw (pos.32)
9.9
Pull the shaft (pos.14) and the piston (pos.2) from the cylinder (pos.1).
9.10
Take the o-ring (pos. 11) off of the cylinder
9.11
Remove sliding ring (pos.9) and o-ring (pos.10) from the piston.
9.12
Remove the snap ring (pos.5). Push the bushing (pos.6) towards the inside of the actuator
cylinder and remove the gaskets (pos.8,12 and 7).
9.13
Repeat the same procedure as 9.11 for the upper cover (pos.13) bushing.
Replacement:
9.14
Clean the actuator parts with a mild detergent suitable for grease removal using a brush, then dry
with a cloth and compressed air.
9.15
Apply grease on the rough parts of back cylinder. Do not apply grease on the machined surfaces.
9.16
Apply grease to the o-ring and install them on the bushings. Insert and fix the bushings into the
cover and cylinder.
9.17
Fill the grease reservoir along the outer rim of the piston.
Important
Apply grease to the gaskets prior installation.
9.18
9.19
9.20
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
Install new gaskets kit.
Apply grease to the inside surface of the cylinder.
Install the sliding ring on the piston.
Install the o-ring on the piston and remove the excess grease.
Insert the piston into the actuator cylinder. Take care of the mounting direction.
Install the upper cover on the actuator, torque the screws to the values indicated on the table
below.
Locking the screw (pos.17) screw the internal screwed shaft (pos.31) to previous position marked
with the pen.
Install the spring (pos.34) end the spring register (pos.37).
Mount the protection cylinder (pos.35) and the cover (pos.18), tighten the nuts (pos.26) and install
the manual override hand wheel (pos.33).
Test the piston movement using an air gun.
Plumb all pneumatic connections and check for air leaks at 1 bar (0,1 MPa) air supply pressure. If
there are no leaks, repeat the test at 7 bar (0,7 MPa).
Clean the excess grease from the shaft.
SC/V
Torque [ Nm]
200
320
14 ( 10,3 lbf-ft )
20 ( 14,7 lbf-ft )
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
C2
ANNEX D_SC/V300-400-500-520: Stem Ext. + No Casting Cyl.
GASKETS REPLACEMENT
SC/V 300-400-500-520: Stem Extended + No Casting Cylinder
Warning
The following instructions must be respected:
- operations must be carried out only by qualified staff (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
During the gaskets replacement:
take care to not damage gaskets grooves during maintenance;
use only the grease type shown in the enclosed table.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
D1
Disassembling:
9.1 Disconnect the actuator from the air supply and ensure the actuator is not pressurized.
9.2 Disconnect the actuator stem from the valve stem
9.3 Disassemble the spring protection upper cover (pos.13) marking the tie rod position, unscrewing the
tie rods and removing all the accessories / fittings where needed.
Warning
Pay attention at the spring action.
9.4
9.5
9.6
9.7
9.8
9.9
9.10
9.11
9.12
9.13
Remove the spring protection cylinder (pos.10)
Remove the spring (pos.23)
Prevent the shaft (pos.16) from rotating while removing the ring nut (pos.17).
Remove the spring register (pos.11/16/18/19) and the bearing (pos.9).
Remove the upper cover (pos.3) removing the nuts (pos.25/27)
Pull the shaft (pos.6) and the piston (pos.4) out off the cylinder (pos.2).
Remove the o-ring (pos.34) from the upper cover
Remove the sliding ring (pos.32) and o-ring (pos.33) from the piston.
Remove the bushing (pos.5) and gaskets (pos.28/29/30/31).
Repeat the same procedure as 9.12 for upper cover bushing.
Replacement:
9.14 Clean the actuator parts with a mild detergent suitable for grease removal using a brush, then dry
with a cloth and compressed air.
9.15 Apply grease on the rough parts of back cylinder.
9.16 Apply grease to the o-ring and install them on the bushings. Insert and fix the bushings into the cover
and cylinder.
9.17 Fill the grease reservoir along the outer rim of the piston.
Important
Apply grease to the gaskets prior installation.
9.18 Install new gaskets kit.
9.19 Apply grease to the inside surface of the cylinder.
9.20 Install the sliding ring on the piston.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
D2
9.21
9.22
9.23
9.24
9.25
9.26
9.27
9.28
9.29
Install the o-ring on the piston and remove the excess grease.
Assemble the piston into the cylinder
Install the upper cover of the actuator and torque the nuts to the value indicated in the table below
Introduce grease into the bushing chamber using relevant lubricator.
Install the spring register (pos.11/16/18), the bushing (pos.16) and tighten the ring nut (pos.17).
Install the spring (pos.23).
Install the protection cylinder (pos.10) and the cover (pos.13), tighten the nuts to the tie rods.
Test the piston movement using an air gun.
Arrange all pneumatic connections and check possible air losses at 1 bar (0,1 MPa) air supply
pressure. If there are no losses, repeat the test at 7 bar (0,7 MPa) air supply pressure.
9.30 Clean the excess grease from the shaft.
SC/V
Torque [Nm]
300
400
500
520
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2017 – SC/V
D3
ANNEX E_SC/V300-400-500-520: Stem Retr. + No Casting Cyl.
GASKETS REPLACEMENT
SC/V 300-400-500-520: Stem Retracted + No Casting Cylinder
Warning
The following instructions must be respected:
- operations must be carried out only by qualified staff (STI operators or
operators qualified by STI are recommended);
- always wear protective clothing, gloves, and eyewear to prevent personal
injury. Check with your process or safety engineer for any additional
measures that must be taken to protect against process media.
During the gaskets replacement:
take care to not damage gaskets grooves during maintenance;
use only the grease type shown in the enclosed table.
-
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2015 – SC/V
E1
Disassembling:
9.1 Disconnect the actuator from the air supply and ensure the actuator is not pressurized.
9.2 Disconnect the actuator stem from the valve stem.
9.3 Disassemble the spring protection upper cover (pos.28) unscrewing the nuts (pos.18) and removing
all the accessories/fittings where needed.
9.4 Remove the spring protection cylinder (pos.27).
9.5 Mark with a pen the spring preloaded (pos.25) position with the screwed shaft (pos.23).
9.6 Prevent the crewed shaft (pos.23) from rotating while removing the spring preloaded (pos.25).
9.7 Remove the spring register (pos.21) and the spring (pos.19).
9.8 Remove the upper cover (pos.8) removing the nuts (pos.18).
9.9 Pull the shaft (pos.11) and the piston (pos.9) out from the cylinder (pos.7).
9.10 Remove the o-ring (pos. 6) from the upper cover.
9.11 Remove the sliding ring (pos.14) and o-ring (pos.10) from the piston.
9.12 Remove the bushing (pos.2) and gaskets (pos.3,4,5 and 15).
9.13 Repeat the same procedure as 9.12 for the upper cover bushing.
Replacement:
9.14 Clean the actuator parts with a mild detergent suitable for grease removal using a brush, then dry
with a cloth and compressed air.
9.15 Apply grease on the rough parts of back cylinder.
9.16 Apply grease to the o-ring and install them on the bushings. Insert and fix the bushings into the cover
and cylinder.
9.17 Fill the grease reservoir along the outer rim of the piston.
Important
Apply grease to the gaskets prior installation.
9.18
9.19
9.20
9.21
9.22
9.23
9.24
Install new gaskets kit.
Apply grease to the inside surface of the cylinder.
Install the sliding ring on the piston.
Install the o-ring on the piston and remove the excess grease.
Assemble the piston into the cylinder.
Install the upper cover of the actuator and torque the nuts to the value indicated in the table below.
Introduce grease into the bushing chamber using relevant lubricator.
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2015 – SC/V
E2
9.25 Prevent the screwed shaft (pos.23) from rotating while install the spring preloaded (pos.25) to
previous position marked with the pen.
9.26 Mount the spring (pos.19) end the spring register (pos.21).
9.27 Install the protection cylinder (pos.27) and the cover (pos.28), tighten the nuts (pos.18).
9.28 Test the piston movement using an air gun.
9.29 Arrange all pneumatic connections and check possible air losses at 1 bar (0,1 MPa) air supply
pressure. If there are no losses, repeat the test at 7 bar (0,7 MPa) air supply pressure.
9.30 Clean the excess grease from the shaft.
SC/V
Torque [Nm]
300
400
500
520
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
70 ( 51,6 lbf-ft )
_____________________________________________________________________________________
STI S.r.l. – Via Dei Caravaggi 15, 24040 Levate (BG) – ITALY
www.imi-critical.com
Manual 5018, rev. 01 06/2015 – SC/V
E3
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