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Summary of Contents for Emerson Shafer ECAT Retrofit
- Page 1 Installation, Operation and Maintenance Manual VA-DC-000-2524 Rev. 0 April 2025 Shafer ECAT Retrofit Emissions Controlled Actuation Technology...
- Page 2 Notes Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 This page is intentionally left blank.
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Page 3: Table Of Contents
Installation, Operation and Maintenance Manual Table of Contents VA-DC-000-2524 Rev. 0 April 2025 Table of Contents Section 1: Introduction Scope .......................... 1 General Information ....................1 Safety Information ....................3 Abbreviation Definitions ..................4 Section 2: Installation Preparation ....................... 5 System Preparation .................... - Page 4 Table of Contents Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Section 5: Troubleshooting Troubleshooting ........................22 Section 6: Maintenance Storage Procedures ....................23 Service Interval .......................23 Lubrication Requirements ...................23 Maintenance Instructions ..................24 Recommended Annual Inspection ..............29 ECAT Schematic ......................30 Table of Contents...
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Page 5: Section 1: Introduction
1.2.1 Overview The Emissions Controlled Actuation Technology (ECAT) is a self-contained, quarter-turn valve operating system that combines proven technologies from Emerson’s valve automation portfolio. The system has been designed for critical shutdown applications where reliability is crucial. The ECAT utilizes a hydraulic accumulator, pressurized with pipeline gas, as a stored energy source in order to actuate the actuator/valve to an open or closed position. - Page 6 Section 1: Introduction Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 1.2.6 Fluid Level in Reservoir The reservoir tank, if supplied, 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.
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Page 7: Safety Information
Installation, Operation and Maintenance Manual Section 1: Introduction VA-DC-000-2524 Rev. 0 April 2025 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. -
Page 8: Abbreviation Definitions
Section 1: Introduction Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Abbreviation Definitions Abbreviations used in this manual and their definitions are listed in the table below: Table 1. Abbreviation Definitions Abbreviation Definition Installation Operation Manual Emergency Shutdown Fail-Safe Double-Acting MAWP... -
Page 9: Section 2: Installation
2.1.1 Delayed Usage If for any reason the system is not to be installed immediately, Emerson 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 for further recommendations. -
Page 10: System Preparation
Section 2: Installation Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 System Preparation 2.2.1 Once the ECAT system is uncrated and cleaned for installation, check to ensure there will be no interference with piping or other structure when the system is properly mounted to the valve. -
Page 11: Lifting The Ecat System
Be sure to use appropriately rated crane/hoist and straps/chains to raise and lower the actuator. 2.3.1 Shafer Rotary Vane Actuator Lifting Use the integrated lifting eyes only to lift and move the ECAT system. Figure 1. Shafer ECAT Retrofit Assembly Lifting Point Installation... -
Page 12: Installing The Ecat Retrofit System
Section 2: Installation Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Figure 2. Shafer ECAT Retrofit Assembly Lifting points CAUTION Never lift the actuator with a valve attached. Always handle actuator/valve assemblies by attaching lifting equipment to the valve only. -
Page 13: Hydraulic Fluid
Installation, Operation and Maintenance Manual Section 2: Installation VA-DC-000-2524 Rev. 0 April 2025 Hydraulic Fluid The ECAT is shipped with or without a reservoir depending on a customer's requirement. The ECAT without a reservoir will utilize the actuator's existing gas hydraulic tank and a tank breather with dipstick will be used to monitor fluid level. - Page 14 Section 2: Installation Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 2.7.2 Pneumatic Isolation Valve and Blow-Down Valve The ECAT is equipped with a pneumatic isolation valve and blow-down valve. This is a one-piece assembly block and bleed valve as shown below. Figure 3.
- Page 15 Installation, Operation and Maintenance Manual Section 2: Installation VA-DC-000-2524 Rev. 0 April 2025 2.7.3 Pipeline Gas connections – Refer to Figure 4. Ensure pneumatic isolation valve is closed. Connect the pipeline gas to the pneumatic isolation valve. Ensure the pneumatic blow-down valve is closed. Remove the bleed plug from blow down valve port.
- Page 16 Section 2: Installation Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 2.7.4 Upstream and downstream Pipeline Gas connections – Refer to Figure 5. Ensure pneumatic isolation valve is closed. Connect the upstream and downstream pipeline gas to shuttle valve. Ensure the pneumatic blow-down valve is closed.
- Page 17 Installation, Operation and Maintenance Manual Section 2: Installation VA-DC-000-2524 Rev. 0 April 2025 2.7.5 Pneumatic Fitting Leak Check With pipeline pressure applied to the pneumatic side of the ECAT circuit, check to ensure there are no leaks at the fittings. Use a leak detection product such as Snoop Liquid Leak Detector ®...
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Page 18: Section 3: Electrical Connections
Section 3: Electrical Connections Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Section 3: Electrical Connections Main Electrical Connections Refer to the project specific wiring diagram for the electrical connections to the Motor Control Center (MCC). Sealing Cable/Conduit Entries Seal the cable and conduit entries in accordance with the National Electric Code or your country standard and applicable local codes. -
Page 19: Section 4: Set-Up/Start-Up Procedure
Installation, Operation and Maintenance Manual Section 4: Set-up/Start-up Procedure VA-DC-000-2524 Rev. 0 April 2025 Section 4: Set-up/Start-up Procedure In addition to this set-up/start-up procedure, the following documentation will be necessary to fulfill all set-up and start-up requirements. General Arrangement drawing Bill of Material Schematic drawing Wiring Diagram drawing... -
Page 20: Initial Check Of The Unit
Section 4: Set-up/Start-up Procedure Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Initial Check of the Unit 4.2.1 Check to ensure all hydraulic tube fittings are tight. Vibration during shipment may have loosened connections. 4.2.2 Visually inspect the unit to make sure tubing, hand valves, gauges and other equipment have not been damaged. - Page 21 Installation, Operation and Maintenance Manual Section 4: Set-up/Start-up Procedure VA-DC-000-2524 Rev. 0 April 2025 4.6.1 Ensure pneumatic isolation valve is open. 4.6.2 Ensure the power oil isolation valve is open. 4.6.3 Open the system bypass valve. 4.6.4 Verify all electrical connections are made per Section 3 of this procedure. Ensure the [Hand (Jog)/Off/Auto] selector switch is set at Off.
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Page 22: Final Start-Up Procedure
Section 4: Set-up/Start-up Procedure Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Final Start-up Procedure The system should already have the pipeline gas pressure applied to the pneumatic side of the system per Section 2.7. Verify the connections and pressure reading on pneumatic pressure gauge, if supplied. - Page 23 Installation, Operation and Maintenance Manual Section 4: Set-up/Start-up Procedure VA-DC-000-2524 Rev. 0 April 2025 The pump is now relieved of pressure and back in neutral. The automatic features of the control circuit can now be used. In the event the hand selector knob is not returned to neutral, after hand pumping, pressure in the cylinder line marked OPEN or the cylinder line marked CLOSE will pilot the selector valve to neutral.
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Page 24: Shafer Speed Control Setup
Section 4: Set-up/Start-up Procedure Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 4.11 Shafer Speed Control Setup The ECAT Retrofit, when installed on a Shafer rotary vane or Bettis™ scotch yoke actuator and control, is equipped with opening and closing speed controls located on the manual hand pump. -
Page 25: Ecat Pump Discharge Manifold Assembly
Installation, Operation and Maintenance Manual Section 4: Set-up/Start-up Procedure VA-DC-000-2524 Rev. 0 April 2025 4.12 ECAT Pump Discharge Manifold Assembly The ECAT is equipped with a pump discharge manifold assembly which includes the pump discharge check valve , the system bypass hand valve and the system hydraulic relief valve. The system hydraulic relief valve is factory set and is equipped with a tamper resistant cover to prevent the relief valve from being adjusted. -
Page 26: Section 5: Troubleshooting
Section 5: Troubleshooting Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Section 5: Troubleshooting WARNING To prevent personal injury, all hydraulic pressure must be relieved from the accumulator before opening any tube lines or attempting replacement operations below. Ensure all customer site location electrical lock out/tag out procedures are followed as required. -
Page 27: Section 6: Maintenance
Emerson’s Product Engineering. Hydraulic fluids, other than those listed below should not be used without prior written approval of Emerson’s Product Engineering. Standard temperature service (-20 to 140 °F / -29 to 60 °C), use ConocoPhillips Megaflow AW HVI 22 Fluid, reference Section 2.6.1. -
Page 28: Maintenance Instructions
Section 6: Maintenance Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Maintenance Instructions Listed below are some of the issues that may arise under normal conditions, and their possible causes and solutions. • Tools: — The tools required for any service or installation are S.A.E. •... - Page 29 Installation, Operation and Maintenance Manual Section 6: Maintenance VA-DC-000-2524 Rev. 0 April 2025 If back-flow through the pump discharge check valve is experienced, the check valve is leaking and should be repaired or replaced. Open the system bypass hand valve and relieve pressure from the lines.
- Page 30 Section 6: Maintenance Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 Stop the hydraulic pump from running by turning the motor control switch to off. Open the system bypass hand valve. Close the pneumatic blow-down valve. Remove and repair the piston seal of the accumulator and/or the thermal volume controller.
- Page 31 Installation, Operation and Maintenance Manual Section 6: Maintenance VA-DC-000-2524 Rev. 0 April 2025 6.4.5 Thermal Volume Controller Target and Switch Adjustment The following instructions detail the setting and adjustment of the motor start/stop switch and target. WARNING The target is not required to make physical contact with the switch for the switch to change state.
- Page 32 Section 6: Maintenance Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 • Adjustable Position Limit Switch and Target Assembly This section details the steps required to set the limit switch and the target of the thermal volume controller. Ensure the [Hand (Jog)/Off/Auto] switch is set to [Off].
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Page 33: Recommended Annual Inspection
• Check the return filter, if included Qualified service personnel are available upon request for problems which our customers do not wish to handle. If the requirements should arise, please feel free to contact your local Emerson service provider. Maintenance... -
Page 34: Ecat Schematic
Section 6: Maintenance Installation, Operation and Maintenance Manual April 2025 VA-DC-000-2524 Rev. 0 ECAT Schematic Figure 10. ECAT with Single Pipeline Connection Maintenance... - Page 35 Installation, Operation and Maintenance Manual Section 6: Maintenance VA-DC-000-2524 Rev. 0 April 2025 Figure 11. ECAT with Upstream/Downstream Pipeline Connections Maintenance...
- Page 36 FCIM-20229-EN © 2025 Emerson. All rights reserved. The Emerson logo is a trademark and service mark of Emerson Electric Co. Shafer™ is a mark of an entity in the Emerson family of businesses. All other marks are the property of their respective owners.
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