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Summary of Contents for rotork CQP
- Page 1 PNEUMATIC COMPACT ACTUATOR (CQP) Single Spring Version & Double Acting Installation, Commissioning & Maintenance Manual Redefining Flow Control...
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Page 2: Table Of Contents
This manual contains important safety information. Please ensure it is thoroughly read and understood before installing, operating or maintaining the equipment. Rotork Fluid Systems reserves the right to modify, amend and improve this manual without notice. Rotork Fluid Systems is not responsible for damage or injury caused by the failure to observe the instructions contained herein. -
Page 3: Introduction
CUSTOMER SERVICE effect) can be available in two different versions: Type A CQP Actuator For technical assistance, please contact the Rotork Fluid Type B CQP Actuator Systems Customer Service: TYPE A Actuator is characterized by the presence of external tie rods. -
Page 4: General Information
Risk Noise >85 dB during operation (RES_05). Preventive measures Operators should wear ear Only Rotork approved replacement parts should be used. Under protections. no circumstances should any modification or alteration be Operators should not stand near carried out on the equipment, as this could invalidate the the equipment during operation. -
Page 5: Labels & Nameplates
OPERATING LIMITS Labels & Nameplates Temperature: -30°C and +100°C for standard applications The following label is applied externally to the Actuator: -20°C to +100°C for PED applications Design pressure: 12 barg Do not use the equipment outside its operating limits ALLOWED FLUID TYPES The pneumatic actuator is designed to be operated with dry air or dry, sweet natural gas with particles filtering ≤... -
Page 6: Handling & Lifting
LIFTING INSTRUCTIONS Handling & Lifting Note: Indication of Weight, Center of gravity, lifting points are Only trained and experienced personnel should reported within specific project documentation. handle/lift the actuator. Consult the project specific documentation before lifting. The actuator is supplied packed on pallets suitable for normal ... - Page 7 Actuator can be lifted and installed also in horizontal position, according to the valve and pipeline installation. To lift the actuator in horizontal mode: Remove the two plugs on threaded holes, that will be used for lifting, on bottom and end flange. Holes for horizontal lifting...
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Page 8: Storage
PRELIMINARY ACTIONS Storage Verify the ATEX classification of the actuator is Rotork Fluid Systems actuator have been fully tested before compatible with the plant zoning. Refer to leaving the factory. actuator nameplate. In order to keep the actuator in good condition until installation, at least, the following measures are recommended: ... - Page 9 by means of the position indicator on the limit switch (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. Lubricate the valve stem with oil or grease, to facilitate assembling.
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Page 10: Removal From Valve
Lift and remove the actuator from the valve. Operation The following instructions must be followed and integrated into End User safety program when installing and using Rotork products. Read and save all instructions prior to installing, operating and servicing this product. - Page 11 DESCRIPTION The main components of the Compact Double Effect Actuator are shown in Figure 1. The actuator consists of a cylindrical body containing a guide tube with vertical grooves connected to the bottom flange and a tube with helical grooves connected to the pneumatic piston. The transformation of linear movement into a rotary quarter turn motion is performed by combining one set of pin and one set of key movements.
- Page 12 Figure 13: Pneumatic Compact Double Effect Actuator – Type B: Figure 12: Pneumatic Compact Spring Return Actuator – Type B: Threaded flanges Parts Description Threaded flanges Parts Description End Cap End Cap Stop nut Stop nut Upper stop bolt Upper stop bolt End Flange End Flange Cylinder tube...
- Page 13 ANGULAR STROKE REGULATION Loosen Stop nut (2). Slowly pressurize the cylinder to detach the stop bolt from the piston. Certain valve incorporate their own stops, for this To reduce the valves the actuator stops positions should coincide actuator stroke, with the valve stop position. screw stop bolt (3) Do not use the actuator outside 90°...
- Page 14 Lower Stop bolt setting To regulate the Lower stop bolt: Unscrew and remove End Cap (1). Use a proper tool to perform the operation. End Cap is provided with a key grip to facilitate screwing/unscrewin Verify Stop nut (2) is correctly tightened Remove the closure cap (if present) Use an Allen key of proper dimension to regulate the lower stop bolt...
- Page 15 PNEUMATIC POWER SUPPLY Opening limit switch Verify allowed supply pressure range on actuator label. Instruction Mechanically Proximity limit Verify medium composition. Contact Rotork Fluid operated Limit switches Systems to check the compatibility with the supply Switches medium. Place the actuator/valve in the fully open position Disengage the open limit cam.
- Page 16 Inlet port/Exhaust port Inlet port/Exhaust port Breathing port Figure 17: Inlet/Exhaust port (Type A) Figure 19: Inlet/Exhaust port and Breathing port (Type B) Refer to specific operating diagram for specific application configuration. Breathing port Figure 18: Breathing port (Type A)
- Page 17 ELECTRICAL CONNECTIONS Check electrical components supply voltage, before start-up. Electrical connection can be performed as follows: Remove power supply. Remove the covers of the electric components. Remove the plastic protection plugs from the cable entries. Use only appropriately certified reduction fittings, cable glands, fittings and explosion-proof cables.
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Page 18: Dismantling & Disposal
Actuators manufactured after 1993 year do not contain asbestos or its by-products. Rotork Sales and Service If your Rotork actuator has been correctly installed and sealed, it will give years of trouble-free service. Should you require technical assistance or spares, Rotork guarantees the best service in the world. -
Page 19: Troubleshooting
Adjust stop bolt setting following instructions in par. Angular Stroke regulation, page 13 Worn seals (Type A actuator) Replace turning flange seal (Refer to PM-CQP- 003) and after replace piston seals (Refer to PM-CQP-004). Attention: Do not perform PM-CQP- 003 and PM-CQP-004 contemporary. - Page 20 003 and PM-CQP-004 contemporary. (Type B actuator) Replace turning flange seal (Refer to PM-CQP- 005) and after replace piston seals (Refer to PM-CQP-006). Attention: Do not perform PM-CQP- 005 and PM-CQP-006 contemporary. For other problems, please contact Rotork Fluid Systems Customer Service.
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Page 21: Periodic Maintenance
Periodic Maintenance Rotork Fluid Systems recommends performing the following checks to help comply with the rules and regulations of the country of final installation: Periodic Maintenance Schedule Maintenance Activity Periodicity Reference Months Years Visual check of external components and control groups. - Page 22 PM-CQP-001 Page:1/1 Item: Actuator Task: Cleaning Equipment, Tools, Materials: Warnings: Air Compressor Project documentation (Design and Operating pressure values) Preliminary Operations: Description: Remove pneumatic supply before proceeding. Remove dust from external surfaces by blowing air. Do not polish/rub non metal surfaces with a dry cloth. The tools and cleaning procedures must not produce sparks or create adverse conditions in the environment during maintenance operations, so as to prevent potential explosion hazards.
- Page 23 Actuator discharges medium gas during normal operation. Pay attention during test. Do not stand near exhaust port. In case of stroke times out of required range refer to Troubleshooting ID 3, page 19, for solutions. In case of problems contact Rotork Fluid Systems Customer Service...
- Page 24 Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description: Cut-off power supply and electric power supply (if present) before performing any operation. Remove the actuator from valve, according to instructions in par. Removal from valve, page 10.
- Page 25 Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description: Cut-off power supply and electric power supply (if present) before performing any operation. Remove the actuator from valve, according to instructions in par. Removal from valve, page 10.
- Page 26 Item: Actuator (Type A) Task: Cylinder seals replacement- Piston seals Equipment, Tools, Materials: Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description (Following) Reassembly • Reinstall cylinder tube (11). • Position end flange (9) with O-ring (10).
- Page 27 Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description: Cut-off power supply and electric power supply (if present) before performing any operation. Remove the actuator from valve, according to instructions in par. Removal from valve, page 10.
- Page 28 Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description: Cut-off power supply and electric power supply (if present) before performing any operation. Remove the actuator from valve, according to instructions in par. Removal from valve, page 10.
- Page 29 Item: Actuator (Type B) Task: Cylinder seals replacement- Piston seals Equipment, Tools, Materials: Warnings: Lifting equipments Spare parts Preliminary Operations: Removal from valve, PM-CQP-003 Description (follow) Reassembly • Replace sliding ring (12) and O-ring (13) • Reinstall cylinder tube (10).
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Page 30: Part List
Part List Figure 20: Part List Pneumatic Actuator Single effect, Single Spring configuration, Type A Item Description Material Item Description Material Cap Nut Alloy steel Sliding Ring PTFE+ Buna-N O-ring Buna-N O-ring Buna-N Stopper plug Carbon steel Hex socket bolt Stainless steel Upper stop bolt... - Page 31 Part. A Figure 21: Part List Pneumatic Actuator Single effect, Single Spring configuration, Type A Item Description Material Item Description Material Cap Nut Alloy steel Sliding Ring PTFE+ Buna-N O-ring Buna-N O-ring Buna-N Stopper plug Carbon steel Hex socket bolt Stainless steel Upper stop bolt...
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Page 32: Grease & Hydraulic Oil Specification
Grease & Hydraulic Oil Specification In general, there is no need to lubricate the actuator because its mechanism is lubricated -for life. The standard grease and oil for Rotork Fluid Systems compact actuators are shown below. If an alternative was specified and/or supplied, please refer to the job specific documentation. - Page 33 All Rotork Fluid Systems actuators are manufactured under a third party accredited ISO9001 quality assurance programme. As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change. For the very latest version release, visit our website at www.rotork.com...
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