Paladon PNS Series Guida

Doc : Q066 Rev : 10

Issued : 01/11/13 Page : 1 of 25

INSTALLATION, COMMISSIONING & MAINTENANCE

MANUAL

PNS, PND & PNC-Series

Pneumatic Scotch-Yoke Valve Actuators

Doc/Rev. Description Pages Date Issued By Approved By

Q066 R 10 Revision 23 15.05.12 MS EB

Q066 R 11 Revision 24 01.11.13 MS BS

Doc : Q066 Rev : 10

Issued : 01/11/13 Page : 2 of 25

Contents Page

1. Introduction ............................................................................................................3

2. Inspection Requirements on Initial Receipt of Actuator................................................3

3. Storage Requirements..................................................................................................3

3.1 Short-Term Storage ..........................................................................................3

3.2 Long-Term Storage...........................................................................................3

4. Actuator Overview ........................................................................................................3

4.1 Standard Components......................................................................................4

4.1.1 Frame..................................................................................................4

4.1.2 Pneumatic Cylinder.............................................................................4

4.1.3 End Stop Screws.................................................................................4

4.1.4 Local Position Indicator.......................................................................4

4.2 Optional Components .......................................................................................4

4.2.1 Spring Cylinder....................................................................................4

4.2.2 Manual Override..................................................................................4

5. Model Number Designations ........................................................................................5

6. Tool Requirements .......................................................................................................5

7. Valve/Actuator Mounting...............................................................................................5

8. Adjusting Open and Closed Valve Positions ................................................................6

9. Preparations for Start-Up..............................................................................................7

10. Manual Override Operation ..........................................................................................7

10.1 Double-Acting Actuator with Handwheel Type Manual Override......................7

10.2 Double-Acting Actuator with Handpump Type Manual Override.......................8

10.3 Spring Return Actuator with Handwheel Type Manual Override.......................8

10.4 Spring Return Actuator with Handpump Type Manual Override.......................8

11. Maintenance ............................................................................................................9

12. Pneumatic Cylinder Seal Replacement........................................................................9

13. Lubrication ..........................................................................................................11

14. Replacement Seal Kits ...............................................................................................11

14.1 Pneumatic Cylinder Spares Kits......................................................................11

14.2 Frame Spares Kits ..........................................................................................11

15. Trouble-Shooting........................................................................................................12

16. Drawings ..........................................................................................................13

16.1 XXX-XXX-FRXXX-00-001-PL .........................................................................14

16.2 XXX-XXX-FRXXX-00-002-PL .........................................................................15

16.3 PNX-XXX-CYXXX-00-001-PL.........................................................................16

16.4 XXX-XXX-SRXXX-00-001-PL.........................................................................17

16.5 XXX-XXX-SRXXX-00-002-PL.........................................................................18

16.6 HYX-XXX-HDXXX-00-001-PL.........................................................................19

16.7 XXX-XXX-SHXXX-00-001-PL.........................................................................20

16.8 HYX-XXX-CYXXX-00-002-PL.........................................................................21

16.9 PNX-XXX-CYXXX-00-002-PL.........................................................................22

17. Spares Kit Ordering & Additional Service Support .....................................................23

18. Functional Safety Data ...............................................................................................24

18.1 Operating Limits and Conditions.....................................................................24

18.2 Normal Operating Condition............................................................................25

18.3 Maintenance Requirement..............................................................................25

Doc : Q066 Rev : 10

Issued : 01/11/13 Page : 3 of 25

1. Introduction

This manual is designed to allow a qualified user to install, commission and maintain Paladon

Systems Ltd PNS, PND and PNC Series valve actuators. This manual should be used in

conjunction with any additional documentation supplied at the time of shipping. Current

versions of all Paladon Systems Ltd documentation are available from

www.paladonsystems.com.

It is the user’s responsibility to ensure that all applicable Health and Safety Legislation is

followed when undertaking any service work. This manual is not designed to supersede or

replace any user’s plant safety or work procedures; in the event of any conflict, please contact

Paladon Systems Ltd or an authorised distributor.

2. Inspection Requirements on Initial Receipt of Actuator

Check paint to ensure that no damage has occurred during transit. In the event of any paint

damage, thoroughly clean the applicable area(s) and repaint as required.

Check that the information detailed on the actuator’s tag plate (comprises of the actuator

serial number, model number, maximum torque output, pneumatic supply pressure range

and valve tag number) matches those detailed on the Sales Order Acknowledgement, Test

Certificates and Delivery Note. In the event of any discrepancies, please contact Paladon

Systems Ltd or an authorised distributor.

3. Storage Requirements

3.1 Short-Term Storage

To ensure optimum performance, the following should be undertaken prior to actuator

storage for any duration:

Check that all pneumatic and electrical connections are suitably sealed to prevent

any environmental ingress.

For any actuator not yet assembled to a valve, place actuator on a wooden pallet to

prevent any damage to the valve coupling flange.

3.2 Long-Term Storage

In addition to the short-term storage requirements detailed above, for long-term storage

the following should be undertaken:

Protect the coupling parts (stem adaptor and coupling joint, coupling flange etc) with

grease or protective oil.

Keep actuators dry and protected against the direct action of weather elements.

Stroke the actuator and ensure all pneumatic and electrical connections are properly

sealed after.

4. Actuator Overview

PNS, PND and PNC Series pneumatic valve actuators are suitable for use with quarter-turn

valves or mechanisms, and have been designed to provide years of efficient and reliable

operation in heavy-duty applications.

The main components of PNS, PND and PNC Series valve actuators are:

Doc : Q066 Rev : 10

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4.1 Standard Components

4.1.1 Frame

The frame contains the scotch-yoke mechanism which converts the linear

movement of the pneumatic piston into a quarter-turn rotary movement. To

protect personnel from injury and the scotch-yoke mechanism from corrosion,

the frame is a fully enclosed carbon steel fabricated construction. To support the

transverse forces generated by scotch-yoke mechanisms, and to ensure correct

alignment of the piston rod, sliding blocks and yoke bushing, the body also

contains a chromium plated guide bar.

4.1.2 Pneumatic Cylinder

Contains the pneumatic piston, which generates the linear movement which is

converted into a quarter-turn rotary movement by the scotch yoke mechanism

housed in the actuator’s frame.

4.1.3 End Stop Screws

Allow precise adjustment of a scotch-yoke mechanism’s angular stroke by

means of two end stop screws. One end stop screw is always located on the

end flange of the pneumatic cylinder. For double-acting actuators, the remaining

end stop screw is either located on the body’s blanking flange, or in the event a

manual override is fitted, on the manual override. For spring-return actuators,

the remaining end stop screw is located on the outer spring-cylinder flange, or in

the event a manual override is fitted, on the manual override.

4.1.4 Local Position Indicator

Connected directly to the scotch-yoke mechanism, the local position indicator

protrudes through the top of the body to provide precise local visual indication of

the actuator’s angular position.

4.2 Optional Components

4.2.1 Spring Cylinder

Supplied with all spring-return PNS, PND and PNC Series valve actuators, the

spring cylinder comprises of a scragged pre-compressed spring contained within

a fully welded carbon steel container. WARNING! The spring cylinder is non-

serviceable; any attempt to disassemble it may result in serious injury or

death.

4.2.2 Manual Override

There are two types of manual override mechanisms which can be provided;

Jackscrew or Hydraulic Handpump. Jackscrew type manual overrides comprise

of a handwheel and jackscrew to create a linear motion, which is converted to a

rotary motion via the scotch-yoke mechanism. Hydraulic handpump manual

overrides comprise of a hydraulic cylinder and handpump to create a linear

motion, which is converted to a rotary motion via the scotch-yoke mechanism.

Doc : Q066 Rev : 10

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5. Model Number Designations

6. Tool Requirements

No special tools are required for the installation, commissioning and maintenance of Paladon

Systems Ltd actuators.

7. Valve/Actuator Mounting

Valve mounting is achieved through one of the following:

Direct mounting using threaded holes on the actuator’s body flange.

Stem adapter mounting using an adapter and coupling joint.

Paladon Systems Ltd actuators can be mounted in any orientation; however, it is common

industry practice to align the centreline of the actuator’s pneumatic cylinder with that of the

valve pipework. NOTE: Certain control components require mounting in a specific

orientation with respect to gravity in order to function correctly.

To assemble the actuator to the valve:

7.1 Check that the coupling dimensions of the actuator are suitable for those of the

valve flange and stem.

7.2 Move the valve to the open or closed position to match the rest position of the

actuator.

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7.3 Thoroughly clean all mounting flanges, taking special care to ensure that all

grease is removed.

7.4 To assist with assembly, lubricate the valve stem with suitable oil or grease.

7.5 Lift the actuator by its lifting eyes and, if possible, ensure that the valve stem is in

the vertical position. NOTE: Do not lift the actuator using slings around the

actuator’s hydraulic or spring cylinders; doing so may result in damage.

7.6 If valve mounting is via a stem adapter and coupling joint (supplied loose),

assemble the coupling joint to the valve stem before proceeding further.

7.7 Lower the actuator onto the valve so that the valve stem slips in the actuator’s

yoke. Fasten the actuator to the valve by means of stud bolts, which are

screwed into the valve’s coupling flange.

7.8 Tighten the nuts to the stud bolts in accordance with the following torques:

Thread Size Torque

M8 20 Nm

M10 40 Nm

M12 70 Nm

M14 110 Nm

M16 160 Nm

M20 320 Nm

M22 420 Nm

M24 550 Nm

M27 800 Nm

M30 1100 Nm

M33 1400 Nm

M36 1700 Nm

7.9 Stroke the actuator to ensure smooth and full opening and closing of the valve.

8. Adjusting Open and Closed Valve Positions

The precise valve open and closed positions are set using the end stop screws. NOTE:

Certain valves incorporate their own end stops. For these types of valves, it is

recommended that the valve's end stops be adjusted to their maximum travel so that the

valve’s end positions are achieved using the actuator’s end stop screws only.

To adjust the open and closed valve positions:

8.1 Loosen the protective nut on each of the end stop screws.

8.2 Move the actuator yoke away from the applicable end stop screw.

8.3 Screw the applicable end stop screw to reduce the actuator’s angular stroke,

unscrew to increase it.

8.4 Move the actuator yoke towards the applicable end stop screw.

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8.5 Check valve position and repeat steps 2 to 4 until desired valve position is

reached.

8.6 Tighten the protective nut on the applicable end stop screw.

8.7 Repeat steps 8.2 to 8.6 for the remaining end stop screw.

9. Preparations for Start-Up

Pneumatic Connections & Considerations

9.1 Prior to connecting the pneumatic supply line(s), check that all pipes and fittings

are in accordance with the plant specifications.

9.2 Check that all pneumatic supply lines are free of any contaminants or debris, and

that they are suitably supported to minimise any stress caused by vibration.

9.3 Connect the pneumatic supply line fasteners.

9.4 Check fasteners for any leaks, and ensure that they are sufficiently tightened to

avoid the chance of becoming loose due to any vibrations created during

operation.

Electrical Connections & Considerations

NOTE: All electrical connections are the responsibility of the user.

9.5 For installations in hazardous areas, ensure all electrical fittings have the correct

hazardous area certification.

9.6 Ensure that the actuators and any control components are suitably protected

against lightning strikes, electrical surges and spikes; and any magnetic fields.

Actuator Stroking

9.7 Stroke the actuator to check that smooth and continuous operation is achieved.

In the event of uneven stroking, or stroking speeds below those detailed on the

test certificate; first check to ensure correct pneumatic supply pressure and flow

rate. Further fault finding procedures can be found in Section 16.

10. Manual Override Operation

10.1 Double-Acting Actuator with Handwheel Type Manual Override

(See Section 16.6, Dwg. HYX-XXX-HDXXX-00-001-PL)

a. Isolate pneumatic supply, depressurise actuator and control system.

b. Remove tubing and fittings from actuator supply inlets to ensure that both sides of

the piston are free to ‘breathe’ to atmosphere.

c. Move the lever on the handwheel frame mounting flange to the ‘ENGAGED’

position.

d. Rotate the handwheel clockwise to close, or anti-clockwise to open the valve.

Doc : Q066 Rev : 10

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e. Once the desired valve position has been achieved, disengage the manual override

by moving the lever on the handwheel frame mounting flange to the ‘DISENGAGED’

position.

f. Re-connect pneumatic supply connections.

10.2 Double-Acting Actuator with Handpump Type Manual Override

(See Section 16.8, Dwg. HYX-XXX-CYXXX-00-002-PL)

a. Isolate pneumatic supply, depressurise actuator and control system.

b. Remove tubing and fittings from actuator supply inlets to ensure that both sides of

the piston are free to ‘breathe’ to atmosphere.

c. Move the 3-way ball valve and cylinder link ball valve levers to the horizontal

position.

d. Move the handpump selector valve to the required flow direction.

e. Operate handpump until desired valve position is achieved.

f. Return 3-way ball valve, cylinder link ball valve and handpump selector valves to

automatic position.

g. Re-connect pneumatic supply lines.

10.3 Spring Return Actuator with Handwheel Type Manual Override

(See Section 16.7, Dwg. XXX-XXX-SHXXX-00-001-PL)

a. Isolate pneumatic supply, depressurise actuator and control system.

b. Remove tubing and fittings from actuator supply inlet to ensure that both sides of

the piston are free to ‘breathe’ to atmosphere.

c. Ensure actuator is in its fail position.

d. Rotate the handwheel anti-clockwise to open the actuator (for fail close ‘SRC’

actuators) or in clockwise direction to close the actuator (for fail open ‘SRO’ type

actuators).

e. Before restoring automatic hydraulic operation, rotate the handwheel in the opposite

direction to the above bullet in order to move the actuator to its fail position.

f. Reconnect pneumatic supply lines.

10.4 Spring Return Actuator with Handpump Type Manual Override

(See Section 16.9, Dwg. PNX-XXX-CYXXX-00-002-PL)

a. Isolate pneumatic supply, depressurise actuator and control system.

b. Remove tubing and fittings from actuator supply inlet to ensure that both sides of

the piston are free to ‘breathe’ to atmosphere.

c. Close the handpump stop valve by rotating its handle clockwise.

d. Operate handpump until desired valve position is achieved.

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e. Reconnect pneumatic supply line.

f. Open the handpump stop valve by rotating its handle anti-clockwise.

11. Maintenance

11.1 All Paladon Systems Ltd actuators have been designed to provide long service

with minimum maintenance; however, a preventative maintenance program is

recommended. Preventative maintenance programs not only help avoid

unanticipated and costly down time, but also typically reduce the overall cost of

ownership.

11.2 It is the user’s responsibility to ensure that all applicable health and safety

legislation is followed when undertaking any maintenance work.

11.3 WARNING! Before commencing any maintenance work, the actuator’s

pneumatic supply line, actuator and associated controls must be fully

depressurised. After system depressurisation, the actuator and controls

must be isolated from the supply line, and from any remote control signals.

Failure to follow any of these steps may result in unanticipated actuator

and valve movement, possibly resulting in serious injury or death.

11.4 Any unauthorised maintenance or modification to the actuator and, where

applicable, the control system may invalidate the warranty.

11.5 Periodic inspection is recommended, specifically;

That smooth valve operation is maintained, and within the required stroking

time.

That there is no external damage to any components.

The pneumatic supply pressure is kept within the specified range.

Pneumatic connections do not show any signs of leakage.

Paint system remains undamaged.

That any dirt or debris is removed from actuator surfaces.

12. Pneumatic Cylinder Seal Replacement

12.1 Remove the blank head flange retaining nuts (see Section 16.3, Dwg. PNX-XXX-

CYXXX-00-001-PL, Item 7 – commercial part).

12.2 Remove the blank head flange (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-

001-PL, Item 5 – manufactured part).

12.3 Slide off the cylinder liner (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-PL,

Item 1 – manufactured part).

12.4 Remove the frame cover retaining screws (see Section 16.1, Dwg. XXX-XXX-

FRXXX-00-001-PL, Item 1 – commercial part).

12.5 Remove the frame cover (see Section 16.1, Dwg. XXX-XXX-FRXXX-00-001-PL,

Item 2 – manufactured part).

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12.6 Loosen the tie rods (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-PL, Item

6 – manufactured part).

12.7 Unscrew the piston rod and slide it off (see Section 16.3, Dwg. PNX-XXX-

CYXXX-00-001-PL, Item 3 – manufactured part).

12.8 Unscrew the frame fixing screws (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-

001-PL, Item 9 – commercial part).

12.9 Remove the rod head flange (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-

PL, Item 4 – manufactured part).

12.10 Remove the O-rings, the piston gasket, the sliding rings and the gaskets; and

clean all O-ring grooves (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-PL,

Items 1, 2, 3, 4, & 5 – commercial part).

12.11 Replace all seals with new ones, and ensure that they are lubricated with grease

(see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-PL, Items 1, 2, 3, 4 & 5 –

commercial part).

12.12 Re-assemble the piston rod (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-

PL, Item 3 – manufactured part) by screwing it into the guide block (see Section

16.1, Drg. XXX-XXX-FRXXX-00-001-PL, Item 6 – manufactured part).

12.13 Tighten the tie rods (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-001-PL, Item

6 – manufactured part).

12.14 Re-assemble the cylinder liner (see Section 16.3, Dwg. PNX-XXX-CYXXX-00-

001-PL, Item 1 – manufactured part) and blank head flange (see Section 16.3,

Drg. PNX-XXX-CYXXX-00-001-PL, Item 5 – manufactured part).

12.15 Uniformly tighten the blank head flange retaining nuts (see Section 16.3, Dwg.

PNX-XXX-CYXXX-00-001-PL, Item 7 – commercial part).

12.16 Replace the paste gasket of the mechanism cover (see Section 16.1, Dwg. XXX-

XXX-FRXXX-00-001-PL, Item 1 – manufactured part).

12.17 Replace the frame cover (see Section 16.1, Dwg. XXX-XXX-FRXXX-00-001-PL,

Item 2 – manufactured part).

12.18 Replace and tighten the frame cover retaining screws (see Section 16.1, Dwg.

XXX-XXX-FRXXX-00-001-PL, Item 1 – commercial part).

12.19 Check for proper actuator operation and for any seal leaks.

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