DOC.SG.EF.EN

DOC.SG.EF.EN
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
EL-O-Matic F-Series
Rack and Pinion Pneumatic Actuators
EL
Matic TM
Table of Contents
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
Table of Contents
1: Safety Instructions............................................................1
1.1 ANSI Safety Messages .................................................1
2: General Information......................................................... 1
2.1 General Application ....................................................1
2.2 Inspection and Maintenance Schedules ......................2
2.3 Parts Ordering ............................................................2
3:
EL-O-Matic F-Series Actuators ..........................................3
3.1 Installation .................................................................3
3.2 Operation ..................................................................4
3.3 Maintenance ..............................................................5
4:
Actuator Accessories ........................................................6
5:
Instructions for Use in Explosive Areas .............................6
5.1 Intended Use ..............................................................6
5.2 Safety Instructions .....................................................6
5.3 Maximum Temperatures ............................................7
Appendix A: EC Declaration of Conformity ............................. 8
Table of Contents
I
Safety Instructions and General Information
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
1. Safety Instructions
Please read these safety warnings, cautions, and instructions carefully before using the
product.
These instructions cannot cover every installation and situation. Do not install, operate,
or maintain this product without being fully trained and qualified in valve, actuator, and
accessory installation, operation and maintenance.
To avoid personnel injury or property damage, it is important to carefully read,
understand, and follow all of the contents of the associated instruction manual,
including all safety cautions and warnings. If you have any questions concerning
installation, or use of this product, contact your Emerson Process Management sales
office before proceeding.
1.1 ANSI 534.6 Safety Messages
Warning Indicates a hazardous situation that, if not avoided, could result in death or serious injury.
Caution -
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
Note/Important
Indicates information considered important, but not hazard-related
2. General Information
2.1 General Application
The EL-O-MATIC F Rack and Pinion actuators are intended for the automation and
operation of quarter-turn valves like Butterfly, Ball and Plug valves.
Rack and Pinion actuators can also be used to operate venting louvers or any other
quarter-turn applications.
This product was intended for a specific range of service conditions: pressure, ambient
temperature, operating media, and possibly other specifications. Do not expose the
product to service conditions or variables other than those for which the product was
intended.
If you are not sure what these conditions or variables are, contact your Emerson Process
Management sales office for assistance. Provide the product type, size, serial number
and all other pertinent information that you have available.
1
Safety Instructions and General Information
Safety Instructions
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
2.2 Inspection and Maintenance Schedules
The EL-O-Matic F Rack and Pinion actuators must be inspected periodically and
maintained as needed. Refer to the maintenance section of manual DOC.IOM.EF.xx for
more detailed information.
The schedule for inspection can only be determined based on the severity of your
service conditions. Your installation might also be subject to inspection schedules
set by applicable governmental codes and regulations, industry standards, company
standards, or plant standards.
In order to avoid increasing dust explosion risk, periodically clean dust deposits from all
equipment.
When equipment is installed in a hazardous area (potentially explosive atmosphere),
prevent sparks by proper tool selection and avoiding other types of impact energy.
Proper care must be taken to avoid generation of static electricity on the nonconductive external surfaces of the equipment (e.g. rubbing of surfaces, etc.). The
actuator's surface temperature is dependent upon process operating conditions.
2.3 Parts Ordering
When ordering parts for older products, always specify the type, size and serial number
of the product and provide all other pertinent information that you can, such as part
material, age of the product, and general service conditions. If you have reconfigured
the product since it was originally purchased, include that information with your
request.
WARNING - Use genuine parts
Use only genuine replacement parts. Components that are not supplied by Emerson Process
Management should not, under any circumstances, be used in any EL-O-Matic product. Use of
components not supplied by Emerson Process Management may void your warranty, might
adversely affect the performance of the product, and could cause personal injury and property
damage.
General Information
2
EL-O-Matic F-Series Actuators
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
3. EL-O-Matic F-Series Actuators
These safety instructions are limited to EL-O-Matic F-Series actuators which are
operating using air or inert gas. If the application requires use of a flammable or
hazardous gas, you must contact your Emerson Process Management sales office for
assistance.
3.1 Installation
WARNING - do not exceed specifications
To avoid personal injury and property damage caused by bursting of parts and to avoid parts
damage, malfunction of control valve, or loss of control of the process caused by excessive
pressure, do not exceed the maximum pressures or temperatures for this actuator, as given in
the applicable product literature or on the nameplate. Use pressure-limiting or pressure-relieving
devices to prevent the actuator pressure from exceeding specified limits. If you cannot determine
the limits for this product, contact your Emerson Process Management sales office before
proceeding.
„„ To avoid personal injury, always wear protective gloves, clothing, and eyewear when
performing any installation operation.
„„ If hoisting the actuator, use a nylon sling to protect the surfaces. Carefully position the sling to
prevent damage to the actuator tubing and any accessories. Also, take care to prevent people
from being injured in case the hoist or rigging slips. Be sure to use adequately sized hoists and
chains or slings to handle the assembly. If an actuator/valve assembly should be lifted, it is
strongly recommended to connect the nylon lifting slings in such way that the actuator and
valve is supported.
„„ Check with your process or safety engineer for any additional measures that must be taken to
protect against process media.
„„ If installing into an existing application, also refer to the WARNING in the Maintenance section.
„„ Do not connect a pressure vessel, to the Actuator, with unrestricted media.
„„ Do not exceed the MAXIMUM stated operating pressures.
„„ Applying pressure directly to the actuator can turn the Actuators shaft/Valve stem.
„„ Applying a control signal to the actuators solenoid can turn the Actuator/Valve assembly.
WARNING - Moving Parts
Stay away from moving parts to prevent serious injury. When test cycling the actuator and valve
assembly by applying pressure to the A or B port, be aware that there are moving parts like pinion
top, actuator to valve coupling and the valve blade, ball, plug, etc.
Isolate the piping system on which an actuator-valve assembly is installed, when removing
this assembly, and relieve any media pressure that may be trapped in the valve cavities before
removing the actuator for maintenance.
3
EL-O-Matic F-Series Actuators
EL-O-Matic F-Series Actuators
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
3.2 Operation
WARNING - Moving Parts
When rotating the actuator stem or shaft with loading pressure applied, use caution to keep
hands and tools out of the actuator travel path. Personal injury and property damage is possible if
something is caught between the actuator stem and other control valve assembly parts.
3.2.1 Operating media
1. Use clean, dry or lubricated air or inert gas.
2. Maximum Operating Pressure (MOP) = 8.3 barg/120 psig
MOP is the pressure required to produce the maximum rated torque at the break
position for all actuators.
Pressure should not exceed MOP during valve rotation.
MOP should be the maximum pressure regulator setting.
WARNING - DO NOT EXCEED SPECIFICATIONS
It can be assured that the housing will not rupture or burst when applying 10 bar of pressure but
the cycle function cannot be guaranteed as it totally depends on the time span to which actuator is
subjected at 10 bar and the frequency at which these pressure peaks occurs. Every time this peak
occurs will, for sure, have a significantly negative effect on the life expectancy of the actuator.
3. Refer to below table on applications where the spring stroke of spring return
actuators is pneumatically operated.
Table 3.1 Maximum pressure on spring stroke of spring return actuators
Spring set
Maximum pressure on spring
stroke of spring return actuators
N=10
7 barg / 101.5 psig
N=20
6 barg / 87.0 psig
N=30
5 barg / 72.5 psig
N=40
4 barg / 58.0 psig
N=50
3 barg / 43.5 psig
N=60
2 barg / 29.0 psig
4. Dew point at least 10K below ambient temperature.
5. For subzero applications take appropriate measures.
6. Mentioned pressure levels are "gauge pressures". Gauge pressure is equal to
absolute pressure minus atmospheric pressure.
EL-O-Matic F-Series Actuators
4
EL-O-Matic F-Series Actuators
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
3.2.2 Operating Temperature range
1. Using standard seals and greases the operating temperature range is -20°C to +
80°C (-4°F to +176°F) as is indicated on the product label.
2. Other medias and temperatures may be used but consult your local Emerson
Process Management sales office for confirmation as to suitability.
3.3 Maintenance
Before mounting or (dis) assembling the Actuator consult the relevant sections of
the installation, operation and maintenance manual for more detailed maintenance
information.
WARNING
Avoid personnel injury or property damage from sudden release of process pressure or
uncontrolled movement of parts. Before performing any maintenance operations:
„„ Always wear protective gloves, clothing, and eyewear.
„„ Disconnect any operating lines providing air pressure, electric power, or a control signal to the
actuator. Be sure the actuator cannot suddenly open or close the valve.
„„ Do not remove the actuator from the valve while the valve is still pressurized.
„„ Vent any pneumatic pressure from the actuator and relieve any actuator spring
pre-compression.
„„ Use lock-out procedures to be sure that the above measures stay in effect while you work on
the equipment.
„„ Never apply pressure to a partially assembled actuator unless all pressure-retaining parts have
been installed properly.
„„ Check with your process or safety engineer for any additional measures that must be taken to
protect against process media.
„„ Do not remove the Pistons from the Actuator Body by using air pressure when the End Caps
have been removed.
„„
5
CAUTION - Pressurized Actuator
Do not turn out the travel stops completely when the actuator is pressurized. When adjusting
the travel stops and the actuator is still pressurized, the travel stops can “shoot” away when
completely turned out.
EL-O-Matic F-Series Actuators
Actuator Accessories
Safety Guide
DOC.SG.EF.EN Rev. 0
„„
„„
March 2014
CAUTION - Spring Force
Spring Return actuators contain springs in a compressed state. Follow these instructions to
release the spring force safely. Normally, the end caps of spring return actuators should be free
of the spring load after 10 full turns (crosswise relaxing) of the end cap screws.
If there is still spring load on the end cap, this might indicate a broken spring cartridge. Stop
this disassembly procedure immediately. Continuing might cause the end cap to “shoot” away
causing serious injury.
Refer to Appendix A of manual DOC.IOM.EF.EN for instructions to safely remove the spring
load before disassembling the end cap form the spring return actuator.
A spring return actuator mounted on a valve, which is stuck in mid stroke, contains a high
spring load which will cause a sudden rotation during disassembly of the actuator versus the
valve or valve bracket. This can cause serious injury to personnel or equipment damage.
Refer to Appendix A of manual DOC.IOM.EF.EN for instructions to safely remove the spring
load before disassembling the actuator from a valve, which is stuck in mid stroke.
4. Actuator Accessories
The actuator may be equipped with components for control and/or feedback. Check
the instructions of these components for installation, operation and maintenance
instructions.
5. Instructions For Use in (potential) Explosive Areas
5.1 Intended use
The EL-O-Matic F-Series pneumatic actuators are intended for use in areas in which
explosive atmospheres caused by mixtures of air and gases, vapours, mists or by
air/dusts are likely to occur. Therefore it may be used in classified Zones 1, 2 (Gases)
and/or 21, 22 (Dust).
5.2 Safety instructions
1. Assembly, disassembly and maintenance, is only allowed at the actuator, when, at
the time of the activity, there are no explosive mixtures.
2. Prevent entry of explosive mixtures into the actuator. We suggest utilizing a
solenoid with a "breather" function on spring return actuators when used in
potentially explosive atmospheres.
3. Provided plastic position indicator is approved for use in potentially explosive (Ex)
gas group IIB areas.
—— In areas where Ex gas group IIC requirements apply, the plastic indicator for
actuator sizes 25 to 350 is approved for use.
—— In areas where Ex gas group IIC requirements apply, do not use the plastic
position indicator (for actuator sizes 600 up to 4000).
Actuator Accessories
6
Instructions for Use in (potential) Explosive Areas
Safety Guide
DOC.SG.EF.EN Rev. 0
March 2014
4. In order to avoid increasing dust explosion risk, periodically clean dust deposits
from all equipment.
5. When equipment is installed in a hazardous area location (potentially explosive
atmosphere), prevent sparks by proper tool selection and avoiding other types of
impact energy.
6. Rack and pinion actuators do not have an inherent ignition source due to electrostatic discharge, but explosion hazards may be present due to the discharge of
static electricity from other valve assembly components.
—— To avoid personal injury or property damage, make sure that the valve is
grounded to the pipeline before placing the valve assembly into service.
—— Use and maintain alternate shaft-to-valve body bonding, such as a shaft-tobody bonding strap assembly.
7. Proper care must be taken to avoid generation of static electricity on the nonconductive external surfaces of the equipment (e.g. rubbing of surfaces, etc.).
8. The paint protection must not exceed 200 μm if the actuator is used in a group IIC
atmosphere. For group IIA or IIB atmospheres the paint protection must not exceed
a thickness of 2 mm (0.08").
5.3 Maximum temperatures
WARNING - surface temperature
The actuator's surface temperature is dependent upon process operating conditions. Personal
injury or property damage, caused by fire or explosion, can result if the actuator's surface
temperature exceeds the acceptable temperature for the hazardous area classification. To avoid
an increase of instrumentation and/or accessory surface temperature due to process operating
conditions, ensure adequate ventilation, shielding, or insulation of these actuator components
installed in a potentially hazardous or explosive atmosphere.
Table 5.1 Temperature range for (potential) explosive areas
Temperature
Temperature
class
TX (surface
temperature)
-20°C(-4°F)…75°C(167°F)
T6
T85°C (185°F)
-20°C(-4°F)…80°C(176°F)
T5
T90°C (194°F)
-20°C(-4°F)…90°C(194°F)
T5
T100°C (212°F)
-20°C(-4°F)…120°C(248°F)
T4
T130°C (266°F)
-40°C(-40°F)…75°C(167°F)
T6
T85°C (185°F)
-40°C(-40°F)…80°C(176°F)
T5
T90°C (194°F)
Ambient range
Valid for actuator model
S = Standard Temperature
H = High Temperature
L = Low Temperature
The specified values are valid with the following conditions:
Maximum cycle frequency of the actuator is 1Hz at a maximum of 50 cycles per hour and at maximum load.
7
Instructions for Use in (potential) Explosive Areas
ROC no 1500
Rev. 0
Emerson Process Management, Valve Automation Inc.
6005 Rogerdale Road, Houston TX 77072 U.S.A.
EL
Matic TM
We hereby declare, that the products specified below meet the basic health and safety requirements.
Product Description :
• EL-O-MATIC F Series - Pneumatic Actuator
Double Acting and Spring Return Actuators
• Double acting types:
FD 25, 40, 65, 100, 150, 200, 350, 600, 950, 1600, 2500 or 4000
• Spring Return types:
FS 25, 40, 65, 100, 150, 200, 350, 600, 950, 1600, 2500 or 4000
Product Variations:
• Product variations of the above mentioned types are still covered by the listed directives and are CE marked.
Serial Number:
• Each Actuator has an identifiable serial number.
EC Declaration of Conformity
Issued in accordance with the
Pressure Equipment Directive
(PED) 97/23/EC
ATEX Directive 94/9/EC
Pressure Equipment Directive (PED)
97/23/EC
• For Gas Group 2 (see Safety Guide DOC.SG.EF.1
section "Operating Media") EL-O-MATIC F Series
pneumatic actuators are excluded from the requirements of the Pressure Equipment Directive 97/23/
EC based on article 1, point 3.6 of the directive.
• For Gas Group 1 pressure media, first consult engineering to check compatibility of pressure media
with the actuator.
• The below listed limited range of EL-O-MATIC F
Series actuator sizes are rated “Sound-EngineeringPractice” or Module A (Internal production control)
and are available on request for use with Gas Group
1 media.
• Double acting types:
FD 25, 40, 65, 100, 150, 200, 350, 600 or 950
• Single acting types:
FS 25, 40, 65, 100, 150, 200, 350, 600 or 950
EC Declaration of Incorporation of
partly completed machinery
Issued in accordance with the
Machinery Directive
2006/42/EC, Appendix IIb
Essential requirements applied and complied with:
• 1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.3.7, 1.5.2, 1.5.3,
1.5.4, 1.5.7, 1.6.1, 1.7.1, 1.7.3, 1.7.4.
• Technical documentation is drafted in compliance
with Appendix VII, section B.
• Before the actuator is put into operation, the machine into or onto which the actuator will be installed,
must comply with the stipulations of the machinery
directive.
• The relevant information concerning the machine
or part will be available in the event of a motivated
request from national authorities.
Applicable standards:
• EN ISO 14121-1:2007
ATEX Directive 94/9/EC
ATEX Marking:
•
II 2G c IIC TX
II 3D c IIIC TX
• For maximum temperature limits and classifications
see Safety Guide: DOC.SG.EF.1 chapter 5, instructions for use in potentially explosive atmospheres.
Applicable standards:
• EN 13463-1:2009
EN 13463-5:2011
UK
Signed :
Name :
Position :
Date :
Place :
_____________________________
S. Ooi
Vice President, Rack & Pinion SBU
& Global Marcom
Emerson Process Management,
Valve Automation Group
2013-12-31
Houston TX, U.S.A.
8
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to our global customers. Choose the WACC or sales
office nearest you:
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T +1 281 477 4100
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Jubail 31961
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7556 BR Hengelo (O)
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T +31 74 256 1010
F +31 74 291 0938
For complete list of sales and manufacturing sites, please visit
www.emersonprocess.com/valveautomationlocations
Or contact us at [email protected]
EL
Matic TM
www.emersonprocess.com/elomatic
All Rights Reserved.
We reserve the right to modify or improve the designs or
specifications of the products mentioned in this manual at any
time without notice. Emerson Process Management does not
assume responsibility for the selection, use or maintenance
of any product. Responsibility for proper selection, use and
maintenance of any Emerson Process Management product
remains solely with the purchaser.
©2014 Emerson Electric Co.
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