Emerson Shafer ECAT User manual

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
April 2021
Shafer ECAT
Emission Controlled Actuator Technologies

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
This page intentionally left blank
Notes
April 2021

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
Table of Contents
April 2021
iTable of Contents
Table of Contents
Section 1: Introduction
1.1 Scope............................................................................................................ 1
1.2 General Information...................................................................................... 1
1.3 Safety Information ........................................................................................ 3
1.4 Abbreviation Denitions ............................................................................... 4
Section 2: Installation
2.1 Preparation ................................................................................................... 5
2.2 Valve Preparation .......................................................................................... 6
2.3 Actuator Preparation..................................................................................... 6
2.4 Lifting the ECAT System ................................................................................ 7
2.5 Installing the ECAT Actuator on the Valve...................................................... 9
2.6 Setting the Stroke Limit Stops ....................................................................... 9
2.7 Hydraulic Fluid ............................................................................................ 10
2.8 Accumulator ............................................................................................... 10
Section 3: Electrical Connections
3.1 Main Electrical Connections ........................................................................ 13
3.2 Sealing Cable / Conduit Entries.................................................................... 13
Section 4: Set-up / Start-up Procedure
4.1 Preparation ................................................................................................. 14
4.2 Initial Check of the Unit ............................................................................... 15
4.3 Initial Connections ...................................................................................... 15
4.4 Initial Pre-Charge ........................................................................................ 15
4.5 Initial Reservoir Fill ...................................................................................... 15
4.6 Hydrostatic Pressure / Function Test............................................................ 15
4.7 Final Start-Up Procedure ............................................................................. 17
4.8 Optional Instrumentation ........................................................................... 17
Section 5: Troubleshooting
Troubleshooting ................................................................................................... 18
Section 6: Maintenance
6.1 Storage Procedures..................................................................................... 19
6.2 Service Interval ........................................................................................... 19
6.3 Lubrication Requirements ........................................................................... 19
6.4 Recommended Annual Inspection............................................................... 20

April 2021
Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
1
Section 1: Introduction
Introduction
Section 1: Introduction
1.1 Scope
This manual is offered as a guide to be used along with locally approved and safe practices to install,
operate, service and maintain the ECAT system. Carefully follow the instructions in this manual and
make sure you install the system correctly and according to your requirements.
1.2 General Information
1.2.1 Overview
The ECAT is a self-contained, quarter-turn, valve actuator that combines proven technologies from
Emerson’s Valve Automation. The actuator has been designed for critical shutdown applications
where reliability is crucial.
The ECAT utilizes a hydraulic accumulator, pressurized with the pipeline gas, as a stored energy
source in order to actuate the actuator / valve open or closed. The self-contained system contains
an electric motor, gear pump, and reservoir. Pressure switches for alarming and return line hydraulic
ltration is available as an option.
1.2.2 Operation
After initial start-up and commissioning procedures have been accomplished, the electric driven
hydraulic pump will keep the power header and all accumulators pressurized to the appropriate
pressure with no intervention from operations personnel.
1.2.3 Maintaining Pressure
Any loss of pressure in the power header line or accumulators, whether caused by external leakage
or actuator movement, will cause the thermal-volume controller rod to move down. This movement
operates the motor control switch to the “Motor On” position, automatically starting the electric
driven hydraulic pump. The pump will run until the hydraulic uid in the power header line and all
accumulators has been replenished. When the header and accumulator have been lled, the thermal-
volume controller rod will rise and operate the motor control switch to the “Motor Off” position.
There is no need for the pump to be started or stopped by operations personnel.
1.2.4 Mechanically Operated Components
The only mechanically operated components on the ECAT system are the motor control switch
located on the thermal volume controller. This switch detects the position of the thermal-volume
controller and relays the information back to the control. The control then starts or stops a motor as
needed. The switch does not require adjustment or maintenance.
1.2.5 Relieving Pressure on the Fluid
High-pressure hydraulic uid can be safely routed back to the reservoir from the accumulator or
actuator units by opening the main accumulator Bypass valve located on the reservoir. Opening this
valve will allow the pressurized uid in the system to be common to the reservoir. This valve should
be opened slowly to prevent the high-pressure uid from foaming due to the velocity through the
hand valve. A hydraulic thermal relief valve is piped in parallel to this hand valve for the purpose
of relieving excess hydraulic pressure in case the control malfunctions or ambient temperature
conditions exceed design limits.

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0 April 2021
2
Section 1: Introduction
Introduction
1.2.6 Fluid Level in Reservoir
The reservoir tank is provided with a stainless steel sight glass level viewer.
1.2.7 Functional Description
The following is a functional description of the ECAT System for valve actuators and a brief
explanation of the main components that make this ECAT system unique. Throughout this
explanation numbers which appear in parenthesis ( ) correspond to item numbers on Schematic
Diagram 11547-S.
The ECAT system provides energy for operation of valve actuators during normal operation as well as
emergency shutdown. This energy is hydraulic power stored in the Accumulator (76). When required,
the Accumulator (76) pushes the hydraulic uid into the power oil header line. The power oil header
line supplies the actuator power for operation.
The hydraulic uid leaving the valve actuator will pass through the return oil header line back into the
Oil Reservoir (60) creating a closed loop system.
The Accumulator (76) gets its power from high-pressure pipeline gas pushing on the accumulator’s piston.
The hydraulic uid, stored in the Accumulator (76), originates from the Oil Reservoir (60). Fluid
is drawn from the Oil Reservoir (60) and through the suction line by a Hydraulic Pump (67). The
hydraulic pump (67) forces the uid through the discharge line and into the Accumulator (76).
The ECAT system has one electric motor driven Hydraulic Pump (67). The pump is controlled by a
motor control switch operated by the Thermal-Volume Controller (77). While in operation, if the
Thermal-Volume Controller (77) moves a small amount actuating the Motor Start / Stop Switch (78)
to the “On” position, the electric motor driven Hydraulic Pump (67) will start to run. The pump will
operate until the Thermal-Volume Controller moves and actuates the Motor Start / Stop Switch (78)
to the “Off” position.
1.2.8 Product Attributes
• Easy installation – ECAT actuator is a totally self-contained system and designed for
compactness and adaptable to new or existing valves
• Designed for Bettis™ or Shafer hydraulic double-acting actuator and controls, including
the handpump
• Shafer™ hydraulic control technology
• Multiple input power options with either AC or DC
• Local open / close control
• Fast speed of operation to fail-safe position if required
• Accumulator suitable for hydraulic and natural gas service
• Operating pressures up to 2220 psi with standard components

April 2021
Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
3
Section 1: Introduction
Introduction
1.3 Safety Information
Safety notices in this manual detail precautions the user must take to reduce the risk of personal
injury and damage to the equipment. The user must read these instructions in their entirety. Failure
to observe these safety notices could result in serious bodily injury, damage to the equipment, void
of the warranty. Take special notice of all tags, warning labels and instructions presented on the
actuator. These may provide more specic and signicant information regarding the actuator than
this general manual.
It is the responsibility of the user to ensure proper safety practices are utilized. Always take
necessary precautions and use proper protective equipment when dealing with compressed gasses,
compressed hydraulic uid, pinch points and electricity.
Safety notices are presented in this manual in three forms (Warning, Caution and Note) as follows:
! WARNING
Alerts user of potential danger; failure to follow the warning notice could result in serious personal
injury or death.
! CAUTION
Identies precautions the user must take to avoid personal injury or equipment damage.
NOTE:
Highlights information critical to the user’s understanding of the ECAT system installation or operation.

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0 April 2021
4
Section 1: Introduction
Introduction
1.4 Abbreviation Denitions
Abbreviations used in this manual and their denitions are listed in the table below:
Table 1. Abbreviation Denitions
Abbreviation Denition
IOM Installation Operation Manual
ESD Emergency Shutdown
FS Fail-safe
DA Double-Acting
MAWP Maximum Allowable Working Pressure
MOP Maximum Operating Pressure
MCC Motor Control Center
LS Limit Switch
PS Pressure Switch
NC Normally Closed
NO Normally Open
CCW Counterclockwise
CW Clockwise
OL Overload
PPE Personal Protective Equipment
GA General Arrangement Drawing
SOV Solenoid Valve
NO Normally Open
NC Normally Closed

April 2021
Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
5
Section 2: Installation
Installation
Section 2: Installation
2.1 Preparation
2.1.1 Delayed Usage
If for any reason the actuator is not to be installed immediately, Emerson Process Management
recommends the following procedures. Failure to comply, with recommended procedures, could
lead to actuator malfunction and possibly void the warranty. For storage procedures exceeding one
year, consult Emerson Process Management for further recommendations.
As shipped from the factory, the ECAT system is an inherently weatherproof unit, providing that all
compartment covers and cable entry plugs remain intact. The actuator should be immediately stored
in a clean, dry warehouse, free from vibration and rapid temperature changes, until it can be installed
and energized.
If the actuator must be stored outside, store it off the ground at an elevation sufcient to prevent it
from being immersed in water or buried in snow. Check for any unpainted or exposed metal surfaces
and make sure they are protected with a coating of grease to prevent any corrosion. Cover the system
to prevent damage from site debris.
2.1.2 Tools and Materials Required
To complete these procedures, you will need the following documentation for the ECAT Actuator and
items indicated in the table below:
• General Arrangement Drawing
• Bill of Material
• ECAT System Schematic
• System Wiring Diagram
Table 2. Tools and Material Requirements
Tools and Material Requirements
Primary Power Source for the ECAT
(check the ECAT System Electrical Diagram for requirements)
Supplemental quantity of hydraulic uid, if needed
(See Section 2.7, Hydraulic Fluid and ECAT specication, for required uid type)
Hand Tools: complete complement of open end (SAE and metric) wrenches, screw drivers Philips
and at blade and a set of hex wrenches
Chains and lifting straps that are inspected and certied for the weight of the ECAT system
(check shipping weights)
Sealant for all cable and conduit entries (approvable by the National Electric Code or your country
standard and applicable local codes)

Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0 April 2021
6
Section 2: Installation
Installation
2.2 Valve Preparation
2.2.1 Remove Valve Gearing if equipped.
2.2.2 If valve is equipped with stops, remove valve stem extension housing. Examine the valve
stops to ensure no foreign material is present that would restrict normal travel of the valve.
Some valves are equipped with inspection ports in the valve housing for ease in examining
the stops.
2.2.3 Check alignment of stem key slot to the position of the valve. Normally with the valve in the
open position, the key slot is in line with the run of the pipeline. With the valve in the closed
position, the key slot should be 90° to the run of the valve.
2.2.4 The ECAT Actuator may be mounted to the valve at any time regardless of whether the valve
is under pressure.
2.3 Actuator Preparation
2.3.1 Once the ECAT Actuator is uncrated and cleaned for installation, check to ensure there will
be no interference with piping or other structure when the actuator is properly mounted to
the valve.
2.3.2 Check that all mounting materials such as fasteners, adapters, brackets etc. are on hand and
ready for use.
2.3.3 Check the actuator and valve to see that they are in the same relative position, that is either
open or closed. If the actuator must be moved, use the Handpump provided.
2.3.4 It is critical that the accumulator is charged with natural gas pipeline pressure prior to
operating the equipment. Refer to Section 2.8 for charging instructions.
NOTE:
Failure to charge the accumulator may cause the accumulator to not function properly.

April 2021
Installation, Operation and Maintenance Manual
VA-DC-000-1952 Rev. 0
7
Section 2: Installation
Installation
2.4 Lifting the ECAT System
NOTE:
All ECAT Considerations
When handling any ECAT actuator, be aware of tubing, accessories, handpump, accumulators, and
control enclosures. Straps and chains can become entangled and cause damage to these components.
NOTE:
Do not use hydraulic tubing and electrical cable for lifting.
! CAUTION
Be sure to use appropriately rated crane / hoist and straps / chains to raise and lower the actuator.
2.4.1 Shafer Rotary Vane Actuator Lifting
Use the integrated lifting eyes only to lift and move the ECAT system.
Figure 1 ECAT System Mounted on the Shafer Rotary Vane Actuator
Lift at these lift points only