rotork RH Series Guide

RH Range
Hydraulic Actuator
Single-Acting and Double-Acting Configuration
Installation, Commissioning and
Maintenance Manual
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RH Range Installation, Commissioning and Maintenance Manual
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Section Page Section Page
Contents
Section Page Section Page
This manual contains important safety information.
Please ensure it is throughly read and understood before
installing, operating or maintaining the equipment.
Rotork reserves the right to modify, amend and improve
this manual without notice.
Due to wide variation in the terminal numbering of
actuator products, actual wiring of the device must
follow the print supplied with the unit.
1. Introduction 3
2. Standards & Regulations 3
3. General Information 4
4. Health & Safety 4
4.1 Residual Risks 4
4.2 Thermal Risks 4
4.3 Noise 4
4.4 Health Risks 4
4.5 Mechanical Risks 4
4.6 Magnetic Risks 5
5. Labels & Nameplates 5
6. Operating Limits 6
6.1 Allowed Fluid Types 6
6.2 Expected Lifetime 6
6.3 Tightening Torque Chart 6
7. Handling & Lifting 7
7.1 Lifting Recommendations 7
7.2 Lifting Instructions 7
8. Storage 9
9. Long Term Storage 9
10. Installation on Valve 10
10.1 Preliminary Actions 10
10.2 Instructions 10
11. Removal from Valve 11
12. Operation 12
12.1 Description 12
12.2 Operating Description 14
12.3 Actuator Code and Design 14
12.4 Manual Override 14
12.5 Angular Stroke Setting 14
12.6 Hydraulic Power Supply 18
12.7 Hydraulic Connections 18
12.8 Electrical Connections 19
12.9 Start Up 19
13. Dismantling and Disposal 20
14. Rotork Sales and Service 20
15. Troubleshooting 21
16. Periodic Maintenance 22
17. Part List 51
18. Grease & Hydraulic Oil Specification 55
18.1 Grease 55
18.2 Hydraulic Oil 56
Single-acting actuator (body sizes 015, 030, 060, 120, 240)
Double-acting actuator
(body sizes 090, 105, 125, 145, 155, 185, 225, 250, 280)
Double-acting actuator (body sizes 015, 030, 060, 120, 240)
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1. Introduction 2. Standards & Regulations
This manual covers maintenance aspects and instructions
specific to the RH range of actuators. General information
on Rotork actuators are described in the User Manual,
delivered separately.
In this manual, warning indications are represented by icons,
per ISO 7010 Safety Signs:
Generic danger
Hand crush / pinch point
Electrocution
Explosive material
Actuators destined for European member states have been
designed, built and tested per the Quality Control System, in
compliance with the EN ISO 9001:2015 standard and with the
following regulations/directive.
• 2006/42/EC: Machinery Directive
• 2014/68/EU: Pressure Equipment Directive (PED)
• 2014/34/EU: Directive for safety equipment and systems
to be used in potentially explosive atmospheres (ATEX)
• 2014/30/UE: Electromagnetic Compatibility Directive
• EN ISO 12100: Machinery Safety Directive
• EN 60079-14: Explosive atmospheres - Part 14: Electrical
installations design, selection and erection
• ISO 80079-36: Non-electrical equipment for explosive
atmospheres - Basic method and requirements
• EN 1127–1: Explosive atmospheres – Explosion prevention
and protection
• ISO 80079-37: Non-electrical equipment for explosive
atmospheres - Non-electrical type of protection
construction safety "c", control of ignition sources "b",
liquid immersion "k"
• UNI EN ISO 7010: Safety Signals
Customer Service
For technical assistance, please contact
Rotork Customer Service:
E-mail: [e-mail]
Rotork Fluid Systems, Porcari,
Lucca, IT tel: [phone]
Rotork plc, Brassmill Lane, Bath, UK. Tel [phone]
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RH Range Installation, Commissioning and Maintenance Manual
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3. General Information
This manual is produced to enable a competent user to install,
operate and maintain Rotork RH single and double-acting
actuators.
The mechanical installation must be carried out as outlined
in this manual and in accordance with any relevant national
standard codes of practice.
Maintenance and operation must be carried out in
accordance with the National Legislation and Statutory
Provisions relating to the safe use of this equipment,
applicable to the site of installation.
Any inspection or repair in a Hazardous Area must not be
undertaken unless it conforms to National Legislation and
Statutory Provisions relating to the specific Hazardous Area.
Only Rotork approved replacement parts should be used.
Under no circumstances should any modification or alteration
be carried out on the equipment, as this could invalidate the
conditions under which certification was granted.
Only trained and experienced operators can install, maintain
and repair Rotork Actuators. Work undertaken must be
carried out in accordance with instructions in this manual.
The user and those persons working on this equipment
must be familiar with their responsibilities under any
statutory provisions relating to the Health and Safety of their
workplace.
Operators must always wear appropriate Personal Protection
Equipment (PPE) in line with the existing plant regulations.
Appropriate usage
Rotork RH range actuators have been specifically developed
to motorize ¼ turn valves, such as ball valves, butterfly valves
or plug valves installed on pipelines for oil & gas transport
and distribution.
Improper use can damage the equipment or cause
dangerous situations for health and safety. Rotork
declines any responsibility for damage to people and/
or objects resulting from the use of the equipment
for applications different from those described in the
present manual.
Before installing the equipment, verify it is suitable for the
intended application. If unsure consult Rotork.
4.1 Residual Risks
Residual risks resulting from equipment risk evaluation
performed by Rotork.
4.2 Thermal Risks
Risk Hot/Cold surface during normal operation.
Preventive measures Operators should wear protective gloves.
4.3 Noise
Risk Noise >85 dB during operation.
Preventive measures Operators must wear ear protections.
Operators must not stand near the
equipment during operation.
4.4 Health Risks
Risk Pressurized fluid ejection during
normal operation.
Preventive measures All fittings must be properly sealed.
All fixing clamps must be correctly
tightened and sealed.
Risk Risk of intoxication (per the type of
medium utilized).
Preventive measures Operators must use P.P.D.s and any
other equipment (breathing apparatus)
based on the type of supply medium.
4.5 Mechanical Risks
Risk Uncontrolled movement (remote
operation). (This risk is applicable
only for actuators provided with
control panel).
Preventive measures Assure that the actuator cannot be
operated remotely. Prior to starting,
remove Hydraulic supply, vent all pressure
vessels, and remove electrical power.
Risk Presence of moving parts (centre body,
valve adapter).
Preventive measures Do not perform start-up or test the
actuator if the cylinder tube is removed.
Risk Loss of stability with possible parts
projection.
Preventive measures Do not disassemble the actuator
in case of malfunctioning. Follow
instructions in the present manual and
contact Rotork.
Preventive measures Foresee periodic maintenance
procedure to verify tightening.
4. Health & Safety
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Risk Presence of potential energy during
dismantling.
Preventive measures Do not disassemble the actuator
during dismantling. Follow instructions
in the present manual and contact
Rotork.
4.6 Magnetic Risks
Risk Risk of magnetic field/disturbance and
exothermic reactions.
Preventive measure The End User shall assure that actuator
and its components are installed
far from magnetic field, electro-
magnetic field, radioactive source,
electroacoustic transducer which could
modify its behaviour.
(This mitigation is applicable only for
actuators provided with control panel)
Avoid maintenance operations with
acid/basic solutions.
The following label is applied externally to the actuator:
1370 LUCCA ITALY
L
CYLINDER CODE:
SERIAL NUMBER :
TESTING PRESS. (PT):
DESIGN PRESS. (PS):
MAX WORKING PRESS.:
bar
bar
bar
L
MIN./MAX DESIGN TEMP.(TS):
CĀ
PED CAT.
:
FLUID:
VOLUME (V):
MONTH/YEAR:
Fig 5.1 Actuator label
The TX surface temperature class is not provided since
the actuator has no internal heat source. Maximum
actuator temperature is the environmental or exercise fluid
temperature, whichever is the greater. Normal operating
temperature range is -30 to +100 °C (-22 to +212 °F).
Temperature range must be specified within the project
specific technical documentation. Special applications beyond
the standard temperature range are available upon request.
ATEX plate does not indicate the maximum environmental
and/or exercise fluid temperature; this information is reported
within the project specific technical documentation.
For CE (PED) marked actuator the following label is also used:
Fig 5.2 Actuator PED label
Label removal is not allowed.
4. Health & Safety 5. Labels & Nameplates
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6. Operating Limits
Temperature: -30 to +100 °C (-22 to +212 °F) for
standard applications
-20 to +100 °C (-4 to +212 °F) for PED
applications
-40 to +100 °C (-40 to +212 °F) for low
temperatures
-60 to +100 °C (-76 to +212 °F) for ultra-
low temperatures
Design pressure: up to 250 Barg, refer to job
documentation.
Operating pressure: refer to job documentation.
Do not use the equipment outside its operating
limits. Verify operating limits on the nameplate.
Prevent external surface temperature to reach the ignition
point in potentially explosive environments.
The actuator surface temperature is strictly dependent on the
temperature of the process fluid used and by the irradiation’s
conditions. The end-user must check the surface temperature
of the assembly, so that this cannot go over the minimum
gas ignition’s temperature, which classifies the area with the
explosion’s risk.
Dust and debris accumulated on the actuator will slow down
its cooling and contribute to the increase of its external
temperature.
6.1 Allowed Fluid Types
RH actuators are designed to be operated with hydraulic oil
ISO 4406 class 16/14/11.
Do not use the actuator in presence of naked flames.
6.2 Expected Lifetime
Expected Lifetime greater than 25 years, in normal service
conditions and with planned maintenance.
6.3 Tightening Torque Chart
RECOMMENDED TIGHTENING TORQUE
(Class 8.8 bolts)
Bolt Size Nm Ft. Lbs
M6 8.5 6
M8 20 15
M10 40 30
M12 55 40
M14 110 81
M16 220 162
M20 430 317
M22 425 313
M24 585 431
M27 785 579
M30 1250 921
M33 1400 1030
M36 1750 1290
M48 5000 3688
M64 9200 6786
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Only trained and experienced personnel should
handle/lift the actuator.
The actuator is supplied packed on pallets suitable for normal
handling.
Handle the actuator with care. Never stack pallets.
7.1 Lifting Recommendations
• The lifting device and the sling must be suitably rated
for the actuator weight and dimensions
• Do not use damaged sling(s)
• The sling must not be shortened with knots or bolts or
any other makeshift device
• For lifting purposes, use only suitable lifting tools
• Do not drill holes, weld eye bolts or add any other type
of lifting device on the actuator external surface
• Do not lift the actuator and valve combination with the
actuator lifting lugs
• Every assembly must be estimated separately for a safe
and correct lifting
• Avoid pulls or abrupt movements during lifting.
Avoid pushing the load
• During lifting operations, do not handle the slings
and/or the actuator
Do not step underneath suspended load.
7.2 Lifting Instructions
Note: Indication of Weight, Centre of gravity,
lifting points are reported within specific project
documentation.
For non-horizontal actuator orientation, please consult
project specific documentation before lifting.
• Prior to lifting the actuator, remove electrical power and
vent all pressure vessels (if present).
• For single-acting actuators, hook the double chain slings
on the lifting lugs, as shown in Fig 7.1.
• For double-acting actuators, hook a double chain sling on
the lifting lug on the Hydraulic cylinder and a textile sling
on the centre body closure flange as shown in Fig 7.2.
The actuator must remain horizontal; balance the load .
• Angle βmust be between 0° and 45° as shown below.
Direction
of Pull
Fig 7.1 Lifting single-acting RH body sizes 015, 030,
060, 120, 240.
7. Handling & Lifting
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Fig 7.2 Lifting double-acting RH body sizes 015, 030,
060, 120, 240.
Fig 7.3 Lifting double-acting RH body sizes 090, 105,
125, 145, 155, 185, 225, 250, 280.
7. Handling & Lifting
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8. Storage
Rotork actuators have been fully tested before leaving
the factory.
Actuators must be kept in good condition until installation.
Follow the measures below:
• Check presence and assembling of dust plugs
• Keep the actuator on shipping pallet until installation
Never put the actuator directly on the ground.
• Actuator must be positioned with the centre body cover
upwards
• Protect the valve coupling area (adapter flange
and coupling joint, etc.) with rust preventive oil
e.g. Mobilarma LT or equivalent
• Protect against weather, cover the actuators with
appropriate polyethylene sheets
• Check the actuator condition every 6 months and verify
the above protection measures remain in place
Remove package only at the installation time.
If long term storage is necessary, further operations must
be carried out to maintain the actuator in a good working
condition:
• Replace the plastic plugs with metal plugs
• Stroke the actuator every 12-months
• Cycle the actuator with a hydraulic supply to the working
pressure indicated on the name plate
• Cycle the actuator with all the existing controls
(i.e. two complete strokes - one open, one closed) at
least 5 times
• Cycle the actuator fitted with hydraulic manual
override by means of the override for 4 complete
strokes
• Disconnect the hydraulic and electric (if present)
supply from the actuator, and carefully close all the
threaded connections of the actuator
• Remove electrical components covers (if present) to
ensure control terminals are clean and free from oxidation
and humidity. Reassemble the covers
• In case of storage for over 12 months prior to installation,
it is recommended to operate the actuator to verify
correct operation
9. Long Term Storage
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10. Installation on Valve
Before proceeding, read and understand the Health and
Safety information.
Note: Prior to performing the following operations, the
valve must be properly secured per Valve Manufacturer
instructions.
Prior to performing any operations check the
operating drawings and TAG numbers.
Consult Rotork for any additional information.
10.1 Preliminary Actions
Verify the ATEX classification of the actuator is
compatible with the plant zoning. Refer to actuator
nameplate.
• The centreline of the cylinder is usually aligned to the
centreline of the associated pipe work
• Ensure all fasteners are adequately tightened, to avoid
loosening during operation, considering the vibrations
induced by the dynamics of the pipeline
• Piping used to provide power to the actuator must be
free from contaminants and debris. Ensure tubing runs
are adequately fastened and supported to minimize
repetitive stress induced the dynamics of the pipeline.
Ensure there are no leaks from any gas connections.
Tighten as required
10.2 Instructions
The actuator assembly on valve can be performed by:
• Mounting directly using the actuator housing flange with
threaded holes
• Using an adapter and a coupling joint between the
actuator and the valve
The assembly position of the actuator must be in accordance
with the actuator design, plant requirements and the valve
model.
To assemble the actuator onto the valve, proceed as follows:
• Verify the coupling dimensions of the valve flange and
stem; they must meet the actuator coupling dimensions
(See document pub019-001)
• Actuator is supplied in the fail position (for single-acting).
Set the valve in the right position per the actuator fail
position. Check the position of the actuator by means of
the position indicator on the centre body or on the limit
switch box (if present)
• Clean the coupling flange of the valve and remove
anything that might prevent adherence to the actuator
flange. Grease shall be completely removed
• Inspect, clean and apply grease on the coupling hole
(valve side of coupling joint)
• Lubricate the valve stem with oil or grease, to facilitate
assembling
• Lift the actuator according to instructions reported in
Handling & Lifting , page 7
• If possible, place the valve stem in a vertical position to
facilitate assembling - in this case the actuator must be
lifted while the coupling flange is kept in the horizontal
position
• If the assembly is done using an adapter and a coupling
joint, assemble the coupling joint onto the valve stem
before proceeding with the assembly of the actuator
• Do not exert any force while lowering the actuator onto
the valve
Installation must be performed by qualified personnel.
Keep hands away from the coupling area.
• Secure the actuator to the valve by means of threaded
fixings (bolts, stud bolts and nuts)
• Tighten bolts or nuts of the connecting stud bolts to the
correct torque, in accordance with the size and material
characteristics of the bolts installed
Support the actuator until fully installed and fixing
bolts are correctly tightened.
Attention: Do not pressurize the actuator/valve
adapter.
• Check for possible damage to the paint-work and repair if
necessary, per painting specification
Fig 10.4 Actuator/valve assembling example
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