Installation, Operation & Maintenance Manual: Virgo Engineers Limited

Installation, Operation & Maintenance Manual
CUSTOMER CONSULTANT P.P. NO. & DATE DT. OF DESPATCH
IMPORTANT NOTE: This manual informs the purchaser of important guidelines ; following these guidelines will be necessary to ensure proper installation & commissioning of the valve. Guarantee conditions are subject to proper installation & commissioning of the valve. GUARANTEE: The product supplied are covered by guarantee period of calendar months from the date of dispatch or calendar months from the date of installation whichever is earlier.
VIRGO ENGINEERS LIMITED

Survey No. 277, Raisoni Induatrial Park, Phase-2, Hinjewadi, Pune-57 Phone : (020) 66744000, Fax : (020) 66744021, E-mail:virgo@virgoengineers.com Website : www.virgoengineers.com
REV. NO. PUBLISHED ON
: 00 :

VALVE AUTOMATION SYSTEM
CONTENTS:
1. GENERAL INSTRUCTIONS 2. IOM FOR BALL VALVES. 3. IOM FOR RACK & PINION ACTUATORS. 4. IOM FOR HEAVY DUTY ACTUATORS. 5. IOM FOR MANUAL OVERRIDE 6. IOM FOR LIMIT SWITCH BOXES.
PAGES
1 TO 6 1 TO 13 1 TO 12 1 TO 6 1 TO 3 1 TO 5
GENERAL INSTRUCTIONS FOR VALVE AUTOMATION SYSTEM
1: INTRODUCTION: The purpose of this manual is to ensure that the Remote Operated Valves / Auto. Control Valves supplied are properly installed and maintained to give trouble-free performance. To familiarize the end users with the role and functioning of various elements like Actuator, Solenoid valves, Limit switches, etc. used to built up a typical control valve automation system. To promote better understanding of the product and sort out the minor problems which may arise on the site. The scope of these instructions covers threepiece and two piece soft seated floating and trunnion mounted ball valves, actuators, manual override, limit switches. For better understanding of these instructions refer the relevant drawings / views of the above elements, where the different parts are identified. 2:RECEPTION AT WORK SITE, STORAGE & HANDLING PRIOR TO INSTALLATION:Previous to shipment all valves will be marked either directly on the body or on a nameplate or both, so as to fully identify in accordance with specifications. All valves are delivered in the Fail Safe Position & with ends provided with blind covers or plastic caps, to avoid the entrance of dust, sand other solid particles during storage/transportation. Valves will arrive to work site packed & protected in accordance with packing instructions (pallets, boxes, cartons, etc.). While valves remain packed care should be taken to store them in a suitable place considering the packing provided. Please note that standard external surface protection on valves is only intended for transportation & storage previous to installation. Once the valve is installed on the line a suitable final protection should be applied depending on environment conditions, operating temperature, line insulation, etc. While unpacking, keep the crates upright. Remove top cover, supporting batons carefully and check the valves for possible damages during transportation. The accessories like handwheel to manual override, pressure gauges that are susceptible to tansit damages are packed and protected separately. Crosscheck the reciept of all the items & quantity as per packing list. After unpacking, valves should be stored on a dry place with good ventilation & dust free atmosphere. Placing the valve directly on the ground or a concrete floor is to be avoided. Valves should never be stored outdoors.
Dont remove the protecting covers until mounting. If covers are removed for examination of valve internals, they should be set back in place immediately.
Caution! Never lift & shift the valves by the actuator / tubing or any other accessory. Use a sling around the valve body.
3:-PRECAUTIONS WHILE MOUNTING, LINE FLUSHING, TESTING STAGE. Valves are bi-directional & can be installed in either position with respect to flow direction. Unidirectional valves will be specifically marked with the flow direction arrow. Important! Normally, it is at the startup of the unit that soft seated valves can get damaged. Do not install valves on pipelines that have not been flushed & cleaned.
Ensure the pipe ends are concentric and aligned to avoid stresses on the valve body. Pipe lines must be supported at regular intervals and preferably near the upstream & downstream of valve to avoid vibrations. Make certain that the valves and gaskets are properly centered to the pipeline. Ensure valve is in desired Fail Safe position. Refer Tagplate & Data sheet/Spec. sheet to crosscheck the same. For on-field reversal of Fail Safe Position refer, IOM for R & P Actuator. Avoid mounting with the actuator underneath the valve. Important! For installation on vertical pipeline, additional supports to actuator are recommended to avoid eccentric forces acting on the stem. This must be strictly followed for heavy actuators. Important! While mounting never separate the valve from actuator. This will disturb factory set strokes and Fail Safe Position of the valves.
Once the valve is installed, do not carry out welding operations on the upstream side. If this is unavoidable, ensure Ball /Plug valve is retained in Open Position. Welding burr may deposit on
the seating members and damage the soft parts during operation. Open & Close the valve a few times before final tightening of counter flanges. Apply the torque referring to the standards for the corresponding bolt sizes. Ensure pneumatic & electric supplies connected to actuator, solenoid valves as per the rated values. Important! Apply only clean & dry plant air to ensure trouble free services of the actuator over a prolonged period
Important! Do not apply excessive force through manual override for extra closing of valve. Since the valve strokes are factory adjusted through actuator, such practice will lead to damages or malfunctioning of the actuator. Check the valve opening/closing through actuator & manual override. Ensure there is no relative movement between the elements assembled. Refasten all the mounting bolts before final testing. After installation and ensuring correct operation, subject the valve for hydro & pneumatic pressure tests by referring the applicable standards. If found necessary, tighten the gland nut at this time. To avoid sudden breakdown, malfunctioning, leakage problems, it is recommended to check all the valves at least once a year for function tests. Replace all soft parts once in two years irrespective of valve performance. By following all the above instructions, the user is assured of trouble free & reliable performance of the products supplied. The following sections will further help the user to have detailed information regarding the functioning of individual element, necessary spares required for maintenance, troubleshooting and the instructions to carry out the same at users end. NOTE:Refer attached Fig. 1, 2, 3, 4 to get general idea of automated systems.
Make provisions to ensure that the signal air pressure(3-15 psi) to pneumatic positioner will never exceed max. allowable pressure 1.5 bar. Electric cables & air tubing must be routed properly. Ensure there are no loads, stresses of cable or pneumatic tube acting on solenoid or positioner. Do not overtighten the pneumatic fittings to actuator, air filter regulator, solenoid valve etc.. Important! Always secure the lids to the solenoid coil, limit switch housings fully to meet the specified services(Weatherproof, Flameproof)
Always while replacing the lids to limit switch housings ensure that the indicator dome is engaged properly with the spindle. Indicator covers to limit switch are of polycarbonate and may get damaged if subjected to heavy impacts or stresses. All unused cable entries to limit switch boxes must be plugged properly to avoid water ingressing. All cam-switches are factory set to receive feedback for valve open/close position. Pay attention not to disturb the cam setting while terminating the cable. For re-setting of cams, refer IOM for Limit Switches. Positioners are factory set & calibrated. However a fine tuning while final testing is recommended. Refer IOM for positioner for detailed instructions, which is not included in this book but is supplied separately with system. Read the instruction plate to manual override carefully & check the operation. Important! Always ensure the manual override declutched prior pneumatic operation. is
FIG. 2

BALL VALVE 1. Introduction
Scope The manual is provided to ensure proper installation, operation & maintenance for the Ball valves manufactured and supplied by Virgo Group of Companies. The valves are identified by marking on the body or on a name plate or both.
3. Dos and Donts

Dos: It is recommended always to use the Installation, Operation & Maintenance Manual before installing, operating or repairing of any Ball Valve(s). Use specified/ recommended MOC for specified application. Before installation of Virgo Made standard valve, it is advised for user to ascertain the compatibility of the material. Periodically ensure the tightness of BodyAdapter joint bolting, operatability & the electrical continuity of the valve. Always use dry, moisture free air while opening the valve with pneumatic actuator or for cleaning purposes. Always wear warm clothes while working with cryogenic liquids. Ensure that thorough ventilation is provided while working on the close equipment for oxygen transfer. Ensure that the end protections are removed before installation of valve in line. Donts:
VIRGO ENGINEERS LTD PUNE, (INDIA)
VIRGO ENGINEERS LTD PUNE, (INDIA)
1.1 Identification of Valve
2. Transportation, Reception and Storage:

While loading & unloading check for any arrow mark on as indicating upward position. Always place the valve preferably on rubber sheets layed on ground. Ensure that all valves ends are covered with protective end caps. Always store the valve under roof, in a dry and clean atmosphere, protected from rain & storm. Before installation of stock valves, it is advisable to conduct hydrostatic/pneumatic test.
Do not drag the valve on bare floor. Do not try to rectify the valve leakage by reworking of seats. Leaking seats have to be replaced with the new Virgo genuine seats. Do not allow any such process which may generate spark; particularly working in H2 or O2 service line or any such inflammable fluids. Do not allow dirt, scales, oil or grease to flow through valve & pipeline for oxygen service. Do not allow to replace (even temporarily) the pressure relieving device which is installed for its intended use by a threaded blind plug. Do not inhale the cold gases/ fumes for long duration while working with cryogenic liquids.
4. Installation:
When taking the valve from the storage a careful check should be made to be sure that the valve has not been damaged during storage period. Especially flange faces should be examined in case of flanged end valves. Valve should be checked for identification purpose to make sure that characteristic Match to those specified for piping specs & for the line where they are to be mounted. Nameplate instruction and tag nos. (where applicable) should give the necessary information
2.1 Storing the Valve 1

BALL VALVES
At this stage valve will have end protector in place and will be the FAIL SAFE Position. Insert valve & locate 3 studs on matching hole on each side. Place the gaskets inside & then locate the remaining stud. Finger tighten all nuts into the respective studs.
Before installation, ensure that the valve end protectors are removed & gasket is placed for Flanged end valves. Clean the valve ends & bore using methylene chloride or trichloroethylene or as per the Customers specification. Clean the pipeline to avoid damage of the soft seat due to debris, scaling, etc. Keep the valve in fully open condition. Never install the Valve with the Actuator on the underneath side in the pipeline.
Now tighten the nut with appropriate size wrench. Tighten nut in a diagonally opposite sequence & using appropriate torque as per standards. Once the installation of the valve in the pipeline is accomplished, unless the pipeline has been flushed previously to valve installation, the valve should not be moved at all from the OPEN position. II. Weld End Valves: Pipe ends must be machined to make them smooth, clean & free from burrs. Keep the valve in the open position. Remove the central body assembly consisting of stem assembly, ball, seat and body seals. Avoid rapid application of excess welding material. During welding, weld with a continuous bid. The welding rod should not exceed 3.2mm dia. Size. After welding, flush the pipe line and valve port to remove impurities formed during welding. Remove any welding spatter also that may have deposited during welding on the inner part of the valve. Welding operations must be done by qualified welder & the welding procedure must be according to relevant ASME welding standards.
4.1 Avoid this mounting position.
Dont allow temperature of the valve body seat area to exceed 200 F (94C). To check the temperature, use thermal chalks. a) Butt Weld End Valves: A proper alignment & a gap g as shown in figure 4.7 to get full penetration of weld upto root. 4.2 Supporting the valve While Installing for: I. Flanged End Valves: Confirm that mating flanges are parallel & aligned perfectly so that no pipeline misalignment force are exerted on the valve body. b) Socket-Weld End Valves: Ensure for proper alignment & a minimum gap of 1.6 mm between the pipe end face and the socket weld ends as shown in Figure 4.4. III. Screwed End Valves:

BALL VALVES
Ensure that threads on pipe are of proper size & type. Clean both male & female thread properly. Use appropriate sealant or Teflon tape while fitting into the pipe line based on pressure rating to ensure complete sealing system with the valve in position, special care should be taken not to damage them. Body of the valve should be tested to 1.5 times of the Maximum Allowable Working Pressure (MAWP) of pressure class.
7. Preventive Maintenance
Periodically check for any damage to valve seats, ball & stem of the valve. While doing periodical checks, it is recommended that the seats, gaskets, seals and packing should be replaced by genuine spares. A repaired valve is always subjected to set of tests before installation.
Emergency Sealant Injection System in Trunnion Mounted Ball Valves: Sealant injection system is provided on valve seat or stem packing area to carryout temporary shut off for maintenance or other purpose. This secondary sealant injection system is to be used only when damage has been caused to the seats & seals by the hard particles or dirt in the process media. Always flush the sealant port with suitable valve cleaner, before injecting sealant. Refer sealant injection fitting arrangement as shown in Figure No. 6.1
While installing unidirectional valve in pipeline, check for the flow direction mark on valve body.
5. Operation of the Valve(s):

Valve should always be rotated through 90 to the fully open or fully closed position. Any intermediate position will rapidly damage internal and seat of the valve. Leaving the valve in the nearly close position should special be avoided as high fluid velocity through the narrow opening will produce erosion of seat of ball & even the body in some cases.
6.1 Sealant Injection Fitting Arrangement
6. Flushing of Lines and testing of valves:

1. If flushing of pipe line has not been made previous to valve installation, then it should be done before the valve are operated for the first time to avoid solid coming to contact with the seats or depositing in the valve cavity. 2. Once the flushing is complete the valve should be operated 3-4 time & then left in the OPEN position. 3. All valves are factory tested & inspected prior dispatch. Should it be necessary to test the piping 3

BALL VALVES
10.General Instructions for Disassembly & & B) ReassemblyTrunnion Mounted Ball Reassembly of Valves : Valves: Before reassembly, inspect the valve for any damage on Body-Adapter & all internals. CAUTION ! Damaged internals to be replaced by genuine . Pipeline and valve must be depressurized by & with recommended parts only.
shutting off the valves & the bleed line, then cycling the valve once & leaving it half open to relieve the pressure from the body cavity
A) DisassemblyTrunnion Mounted Ball Valves:

1.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Disconnect pneumatic and electric supply to automation assembly. Remove it(Including bracket & coupling) from the valve. Valve shall be positioned vertically by resting body side flanges on clean ground surface (preferably covered with rubber sheet). Open the body adapter joint by loosening the Nuts in crisscross pattern Remove the body seal from the body adapter and body gasket from the body. Remove the ball from the body & the seats from body & body adapter. Remove the stem by removing stem holding devices as applicable. Push stem into Body cavity & take it out. Remove all stem seals. All the components should be stored in a clean place. Remove the trunnion by removing the cap screws. Remove the antistatic spring, the thrust washer (trunnion), the gasket (trunnion) & the O-ring (trunnion). Remove the ball from the body. Warning! Lifting & shifting of ball must be carried with utmost care, even a minor scratch on the ball surface may affect performance of the valve.
13. Remove bush bearing from bearing bore in ball on both stem & trunnion side. 14. Remove the O-ring (body adapter) & gaskets (body) from the body adapter. 15. Remove the seat + insert from the body & body adapter. 16. Remove the springs, seat O-ring from the seat. 17. Where applicable the sealant injection fittings [(stem) & (seat)] & drain/vent plugs may be removed for cleaning.
1. Follow the same step as mentioned in A) 2). 2. Apply suitable coat to bolting to prevent corrosion. 3. Insert body seats in position. 4. Insert the stem seal bottom & the stem O rings on the stem & install the stem from inside the body. 5. Insert the top stem seal, the spacer, the disc springs or stem bush into the stem as applicable. 6. Ensure proper locking of stem with lock nut, washer or mounting plate as applicable. 7. Align stem A/F parallel with the body bore. 8. Gently slide the ball over the stem A/F. 9. Place seal & seat in body adaptor. 10. Position the gasket with the body & position studs. 11. Assemble the valve by putting adapter on the body & tighten the body nuts in a crisscross pattern. 12. Put the automation in position into body & tighten them. 13. Ensure open and close smooth operation of valve. 14. Fit the antistatic spring, the thrust washer (trunnion), the gasket (trunnion) & O-ring (trunnion). 15. Fit the bush bearing into the recess in ball on both stem & trunnion side. 16. Lift the ball & lower it into the body in the appropriate position. 17. Locate the trunnion in ball recess & tighten the cap screws. 18. Lift the valve & place it so that the direction of the flow axis is horizontal. 19. Locate the dowel pins & place the stem housing on the body, so that the stem housing fits into the bush bearing & stem flats locates in the ball slot. 20. Place & tighten the cap screws for stem housing. 21. Fit the body adapter gently upto with seat to the body & tighten the nuts. Put the studs in position into body & tighten them. 22. Fit the gasket (stem) in the stem housing recess. 23. Place the gland on the stem housing & tighten the cap screws. 24. Fit the stem key in stem key way. 25. Place the coupling on the stem, place the bracket on the stem housing, fit the studs & 4

BALL VALVES
6. tighten the nuts. Place the actuator on the coupling & the bracket, fit the studs & tighten the nuts. 26. Where applicable, fit sealant injection fittings [(stem) & (seat)] & the drain/vent plugs. 27. Rotate the ball slowly back & forth to a full quarter turn. This will allow the seat to assume its permanent position & shape against ball & body. A fast turning motion may damage the seat before it has a chance to form a proper seal. washer or mounting plate as applicable. 7. Align stem A/F parallel with the body bore. 8. Gently slide the ball over the stem A/F. 9. Place seal & seat in body adaptor. 10. Position the gasket with the body & position studs. 11. Assemble the valve by putting adapter on the body & tighten the body nuts in a crisscross pattern. 12. Put the automation assembly in position into body & tighten them. 13. Ensure smooth operation of valve during opening and closing.
C) DisassemblyFloating Ball Valve(two piece construction):

1) Disconnect pneumatic and electric supply to automation assembly. Remove it (Including bracket & coupling) from the valve. 2) Valve shall be positioned vertically by resting body side flanges on clean ground surface (preferably covered with rubber sheet). 3) Open the body adapter joint by loosening the Nuts in crisscross pattern. 4) Remove the body seal from the body adapter and body gasket from the body. 5) Remove the ball from the body & the seats from body & body adapter. Warning! Lifting & shifting of ball must be carried with utmost care, even a minor scratch on the ball surface may affect performance of the valve. 6) Remove the stem by removing stem-holding devices as applicable. 7) Push stem into Body cavity & take it out. 8) Remove all stem seals. 9) All the components should be stored in a clean place. D) ReassemblyFloatingBall Valves(two
E) DisassemblyFloating Ball Valve (Three piece construction):

1. The swing-through design of three piece ball valve facilitates on-line repair And replacement of soft parts. 2. Disconnect pneumatic & electric supply to automation assembly. Remove it (including bracket & coupling) from the valve. 3. Remove the valve body Nut Bolt (3 no .s) and only loosen but do not remove remaining nut-bolt. 4. Keep the valve in the full OPEN position. 5. The Body can now be sung out of the pipeline. 6. Remove the Body Gasket & Seat on both side 7. Rotate the stem to turn Ball to full CLOSE position. Push out the ball from the body. 8. Remove the Stem Nut , Disc Springs , Spacer , over the stem. 9. Push the stem to remove it from inside the body. Remove the Bottom & Top Stem Seal from the body. 10. Clean the ball, valve body & end pieces internal with suitable & permissible liquid like petrol, kerosene etc and cloth. Clean the seat and seals with cloth only. Place all the above part on the clean & dust free platform 11. Examine metallic part to ensure that there are no scoring on the sealing surfaces. Check the seals for scratches/wear. 12. All part that are recommended as seal kit to be replaced with new one whenever the valve is disassembled. F) Reassembly Floating Ball Valve
piece construction):
Before reassembly, inspect the valve for any damage on Body-Adaptor & all internals. Damaged internals to be replaced by genuine & with recommended parts only.
(Three piece construction):

1. Place the Bottom Stem Seal , Stem , Top Stem Seal ,Disc Spring , Spacer & Stem Nut by following step # 7 & 8 at E) in exactly reverse order. 2. Tighten stem nut so as to pressurize / compress the disc springs. Over tightening may result in stem locking. 3. Slide the ball in the body in such a way that 5
1. Follow the same step as mentioned in A) 2). 2. Apply suitable coat to bolting to prevent from corrosion. 3. Insert body seats in position. Insert the stem seal bottom & the stem O rings on the stem & install the stem from inside the body. 4. Insert the top stem seal, the spacer, the disc springs or stem bush into the stem as applicable. 5. Ensure proper locking of stem with lock nut,

BALL VALVES
the stem location slot on the ball locates in the flat of the stem. Rotate the stem to keep ball in the full OPEN position. Fit the seats & Body Gaskets on either side of the ball. Ensure the seats & seals are located properly and will not foul with the end piece and then swing the body to its original position. Pass the Body Bolts & finger tighten the Nut Tighten all the nuts equally and diagonally using appropriate wrenches & torques. Subject the valve for pressure testing, if any leakage observe through body joints or gland, further tighten the body nut and stem nut. Re-install the automation assembly and check the operation.
4. 5. 6. 7. 8.

BALL VALVES
10. Exploded view: Two Piece Design Floating Ball Valves ( With Double D Stem)
Parts List
ITEM 01 02 03 04 * 05 * 06 * 07 * 08 * 09 * 10 11 12 13 14 15 PART NAME Body Body Adapter Ball Stem Seat Body Seal Body Gasket Stem Seal Bottom Stem O Ring Stem Seal Top Spacer Ring Disc Spring Stem Nut Stud Nut RECOMMENDED TIGHTENING TORQUES, Kg.m (Nm) Thread Size M8 M10 M12 M14 M16 M18 M20 M24 M27 M30 Property Class 8.8 2(20) 4(40) 7(69) 11.3(111) 17.2(168) 24.4(239) 33.5(329) 57.9(568) 87.5(858) 115.9(1137) Property Class 10.9 2.9(28) 5.7(56) 10(98) 15.9(156) 24.2(237) 34.3(336) 47.2(463) 81.5(799) 123(1207) 163(1599) B7/B7M 2(18) 3(30) 5(51) 11(103) 12(121) 20(194) 24(236) 42(408) 61(597) 83(814)
Note: Ensure that all the nuts/bolts are tightened to the Torque Values as specified in this Table. For B8/B8M consider Tightening Torque 20% less than above values
* Recommended spare parts.
Note: Always use the genuine spare parts to make sure that the valve functions as intended.

BALL VALVES 11. Exploded view: Three Piece Design Floating Ball Valves
Parts & Fastener Torques

ITEM 01 02 03 04 * 05 06 * 07 * 08 * 09 10 11 12 13 14 PART NAME Body Pipe End Ball Stem Seat Seat Ring Body Gasket Stem Seal Bottom Stem Seal Top Spacer Ring Disc Spring Stem Nut Studs Nuts RECOMMENDED TIGHTENING TORQUES, Kg.m (N.m) Thread Property Size Class 8.8 M8 2 (20) M10 4 (40) M12 7 (69) M14 11.3 (111) M16 17.2 (168) M18 24.4 (239) M20 33.5 (329) M24 57.9 (568) M27 87.5 (858) M30 115.9 (1137) Property Class 10.9 2.9 (28) 5.7 (56) 10 (98) 15.9 (156) 24.2 (237) 34.3 (336) 47.2 (463) 81.5 (799) 123 (1207) 163 (1599) B7/B7M 2 (18) 3 (30) 5 (51) 11 (103) 12 (121) 20 (194) 24 (236) 42 (408) 61 (597) 83 (814)
Note: Ensure that all the nuts/bolts are tightened to

the torque values as specified in this Table. For B8/B8M consider Tightening Torque 20% less than above values
* Recommended spare parts. Note: Always use the genuine spare parts to make sure that the valve functions as intended. 8

BALL VALVES 12. Exploded view: Two Piece Design Floating Ball Valves
Parts List
ITEM 01 02 03 04 * 05 * 06 * 07 * 08 * 09 10 11 12 13 PART NAME Body Body Adapter Ball Stem Seat Body Gasket Body Gasket Stem Seal Bottom Stem O Ring Stem Bush Body Stud Body Nut Stem Key RECOMMENDED TIGHTENING TORQUES, Kg.m (Nm) Thread Size M8 M10 M12 M14 M16 M18 M20 M24 M27 M30 Property Class 8.8 2(20) 4(40) 7(69) 11.3(111) 17.2(168) 24.4(239) 33.5(329) 57.9(568) 87.5(858) 115.9(1137) Property Class 10.9 2.9(28) 5.7(56) 10(98) 15.9(156) 24.2(237) 34.3(336) 47.2(463) 81.5(799) 123(1207) 163(1599) B7/B7M 2(18) 3(30) 5(51) 11(103) 12(121) 20(194) 24(236) 42(408) 61(597) 83(814)
Note: Ensure that all the nuts/bolts are tightened to the Torque Values as specified in this Table.
For B8/B8M consider Tightening Torque 20% less than above values. * Recommended spare parts. Note: Always use the genuine spare parts to make sure that the valve functions as intended.

BALL VALVES
13. Exploded view: Two Piece Design - Trunnion Mounted Ball Valves
Note: Always use the genuine spare parts to make sure that the valve functions as intended. 10

BALL VALVES
14. Exploded view: Three Piece Design - Trunnion Mounted Ball Valves
Note: Always use the genuine spare parts to make sure that the valve functions as intended. 11

BALL VALVES Ordering the spares
When ordering for spare parts, always convey the following information. Size of the valve Valve rating Sr. No. / Batch No. Mfg. Date Part No. Name of the part Number of pieces required. P. O. Number
Available on name plate or body of the valve
Available on general arrangement drawing
Trouble Shooting
The following table lists the possible malfunctions that might occur after prolonged use. Leakage through a closed Valve Irregular ball movement Valve too hard to operate / valve torque too high Possible fault Damaged ball surface Damaged seats Ball might not be closed fully Impurities between the ball and seats or ball body cavity and ball Seats. Damaged seats High application pressure / temperature Foreign particles in Valve Error in valve sizing or flow of fluid with high velocity. Gland nut loose Damaged stem, stem sealing surface Damaged stem seal Damaged O ring or breakage of gasket Relaxation of studs due to gasket creep Actions Replace the ball. Replace seats. Check ball Open/Close settings. Flush the ball from inside. Clean the sealing surfaces and seats. Replace the seats. Confirm the application pressure /temperature rating. Clean the internals. Confirm valve sizing with respect to flow. Tighten gland nut. Replace the stem. Replace the stem seal. Replace O ring/ gasket. Retighten the studs evenly in criss-cross manner
Water hammer or noisy operation Leakage through stem
Leakage through bodyadaptor joint
12

BALL VALVES
Note: Selection and use of the valve for a specific application requires close consideration of detailed aspects. Due to the nature of the product, this manual cannot cover all the individual situations that may occur when installing, using or servicing the valve. Warranty: Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury or damage attributable thereto is limited to making goods by replacement or repair defects which under proper use appear therein and arise solely from faulty materials and workmanship within a period of 18 calendar months after the original goods shall have been first dispatched or 12 calendar months from the date of commissioning, whichever is earlier provided that such defective parts are returned free to our works for examination. The undertaking shall exclude any and every other obligation.
Caution!
Virgo does not assume responsibilities for any liabilities/damages arriving out of wrong application of its valves, or imprudent operations carried out by inexperienced operators, or which does not comply with this manual ,or instructions provided by Virgo. The valves shall be appropriately used for the purpose they are built, or applications they are supplied. Use of standard valves for special applications is not recommended unless it has been communicated and agreed to by Virgo. Valves shall be operated and maintained strictly in accordance with the procedures. Operation or maintenance outside these procedures constitutes abuse of the product and voids all warranty and claims.
13

2V SERIES RACK & PINION ACTUATORS
1. General: This manual contains the important information regarding the installation, operation and troubleshooting of the Virgo 2V pneumatic actuators. Please read these instructions carefully before operating the actuator. Warnings! It is important that the actuator should only be used within the pressure limits indicated in our technical specifications. Operating the actuator over pressure limits will damage internal parts as well as cause damage to the housing. Operating the actuator over temperature limits will damage internal and external components (disassembly of spring return actuator may become dangerous). Operating the actuator in corrosive environments with incorrect protection may damage the internal and external parts. Do not disassemble the individual spring cartridges. Disassembly may result in personal injury. Isolate all airlines and make sure that actuator air connection is vented before installation or servicing of the actuator Do not remove end caps or disassemble the actuator while the actuator is pressurized. Before installing onto a valve, make sure that the rotation of the valve and the actuator are the same and that the position indicator orientation is also correct. If the actuator is in a system or used within safety devices or circuits, the customer shall ensure that the national and local safety laws and regulations are observed. External Travel Stops: 5 adjustment on 90 stroke. 3. Installation: 1. Actuator should be stored indoor until ready for use. Check that the non-connected ports of actuator are plugged properly with plastic cap/silencer to avoid ingress of dust, dirt, moisture into actuator. 2. Prior to assembly, check the mounting surfaces, coupling, bracket to ensure proper fit. Apply little grease to coupling surface. 3. Ensure that the desired failure mode is correct (Refer to figure no. 1,2 & 3). The Virgo 2V actuator typically operates counter clockwise to open and clockwise to close, it is possible to change this style of operation. If the spring return actuator is not set up in the configuration desired, follow the disassembly procedure section 5.2. Reverse the orientation of the pistons, then reassemble following the assembly procedure, section 5.3. 4. Ensure that the valve is in the fail safe position. 5. Secure the valve with stem vertical. Bolt the bracket to valve and place the coupling on valve stem. Use key/dowell pin (according to valve stem design) to engage coupling with the valve stem. Be sure that there is no play between valve stem & coupling. 6. Continue to lower the actuator until it rests on the bracket mounting surface. Important!
Never hammer actuator/pinion for complete engagement of pinion and coupling. Hammering damages / deforms pinion permanently. If actuator cannot be lowered easily, file / grind coupling square faces lightly to ease the engagement
2. Technical Data: Operating Media: Dry or lubricated air, noncorrosive and inert gas, or light hydraulic oil. Air Supply: 8 bar (116 PSI) Maximum. Temperature: Standard: -4 F to 175F (-20C to 80C) Viton O Rings : -4 F to 300F (-20C to 150C) Siilicon O Rings : -40 F to 175F (-40C to 80C) Lubrication: Factory lubricated for the life of the actuator under normal conditions. Construction: Suitable for indoor and outdoor use.
7. To align the bolt holes, it may be necessary to turn or to stroke the actuator a few degrees. Bolt the actuator to the bracket by evenly tightening all four bolts in diagonal pattern. 8. Stroke the actuator to check proper open and close valve position. If required, further adjust the stroke adjustment bolts following assembly section 5.3.5. Stroke adjustment bolts can be adjusted by up to 5. 9. Also assure proper operation of actuator with no binding of coupling. Check for proper alignment of actuator, coupling and valve stem along the axis to ensure that pinion is rotating in exactly circular profile(90.sector). If not so realign the assembly and fix it properly. 10. Ensure that there is no relative movement between valve to bracket and bracket to actuator. 1

11. Recommendation: When the valve automation assembly is mounted with valve stem axis horizontal, additional adequate supports must be provided to the actuator. Failure to do the same could lead eccentric loads on the valve stem. This must be strictly followed particularly with heavy actuators. 12. If the actuator is equipped with some accessories like limit switches, speed control valve, adjust them at this time. 13. Mount the actuator to the valve as per the desired orientation (parallel or perpendicular to the pipeline). 14. Connect a regulated air supply to the NPT fitting in the actuator housing.
Caution! The maximum operating is116 psi (8 bar)
cap cavities directing airflow into/out of the end cap area. 4.1 Double Acting (Figure 1): (Double air connection required to achieve both actions- opening & closing). Air supplied through port A forces the piston away from each other causing the pinion to rotate counter clockwise (with exhaust air exiting through port B). Air introduced through port B forces the piston towards each other causing the pinion to rotate clockwise (with exhaust air exiting through port A).
pressure
3.1 Changing Actuator Orientation: Actuator can be mounted parallel or perpendicular to the pipeline axis. The standard practice is to mount actuator parallel to pipeline. However factory assembly is carried out based on customers data/spec. sheet. By reffering the following instructions, actuator body orientation can be changed on field: 1) Disconnect pneumatic and electric supply to actuator, solenoid valve to release the air from actuator completely. Ensure the valve is in the desired fail safe position. 2) Remove mounting bolts at the bottom of actuator. 3) Lift actuator till it gets free from the coupling. 4) Rotate actuator by 90 and lower it over coupling. 5) Rest the actuator fully on bracket surface and secure it with mounting bolts Fasten the bolts. 6) Stroke the actuator 2-3 times pneumatically to ensure proper functioning. 4. Operation: The Virgo 2V actuators have simple operational characteristics. Port A (facing the ports and reading right to left) is connected to the interior cavity between the pistons directing the airflow into/out of the interior cavity. Port B is connected to the end
4.2 Spring Return: Single air connection required for one action, the reverse is achieved with springs 4.2.1 Fail Clockwise (FCW) (Standard Scope of Supply) (Figure 2): Air introduced through port A forces the piston away from each other, compressing springs and causing the pinion to rotate counter clockwise (with exhaust air exiting through port B). Upon loss /release of air pressure, springs forces the piston towards center position causing pinion to rotate clockwise (FCW) (with exhaust air exiting through port A). 4.2.2 Fail Counter Clockwise (FCCW) (Figure 3) : Air introduced through port A forces the piston away

from each other, compressing springs and causing the pinion to rotate clockwise (with exhaust air exiting through port B). Upon loss /release of air pressure, springs forces the piston towards center position causing pinion to rotate counter clockwise (FCCW) (with exhaust air exiting through port A). 4.3) Changing fail safe position: Valve automation system is always assembled to meet desired fail safe position (fail to open/close) as per customer spec. sheet. However the special design feature of actuator offers on-line conversion of fail safe position. Refer the following instructions: 4.3.1) Assembly with valve + Actuator: 1) Disconnect pneumatic & electric supply to actuator and ensure air is not blocked / trapped inside actuator. 2) Remove mounting bolts from actuator bottom and lift the actuator till it is disengaged fully from the coupling. 3) Rotate the valve stem through 90 to change its position(close to open or vice versa). 4) Re-install actuator. Secure it properly by tightening the mounting bolts. 5) Stroke actuator pneumatically 2-3 times to ensure the desired fail safe condition is achieved. 6) If limit switches, positioners are provided, readjust the same. Important! The above method holds good only for quarter turn, bi-directional valves like Ball valve, Butterfly valve with centric disc design, plug valve. By changing fail safe condition, the 90 sector of valve operation gets shifted. The same is not recommended for the valves with special design like Butterfly valve with eccentric disc, Segment Ball valve, Unidirectional valves. Adopting above method for such valves may damage the valve permanently. For changing fail safe condition of such valves , change the piston orientation on both sides by 180. 4.3.2) Assembly with Valve + Manual Override (Gear Box) + Actuator: 1) Follow steps #1 through 6 referred in 4.3.1 2) Refer IOM for Manual Override to follow the further instructions to re-align gear box after changing fail safe condition of valve. 5 Maintenance: 5.1 General : Virgo 2V actuator can be supplied with Metric / UNC fasteners. Under normal operating conditions, the actuator requires only periodic observation to ensure proper adjustment. Parts included in seal kit & repair kit are indicated on table 3. 5.2 Disassembly: When disassembly of the actuator is required for maintenance, remove the actuator from the valve. Ensure proper lifting procedures are followed when moving or carrying actuators. .
Caution! Do not use M5 VDE/VDI mounting holes for lifting the actuator
When disassembling the Virgo 2V actuators, use caution and be certain that the actuator is free from accessories and the air supply is disconnected. When the actuator is a spring-return unit, make sure that the actuator is in the failed position before disassembling. 5.2.1) Removal of Local Position indicator (28) (Figure 4) :
a) Remove the counter sunk screw (29), if fitted. b) Remove the Local position indicator (28) from the pinion (05). It may be necessary to pry gently with a screwdriver.

5.2.2) Removal of Top Cover Plate (19) Assembly (Figure 5) : 5.2.4) End Cap (02,03) Disassembly (Figure 7):
a) Remove the counter screws (17). b) Remove the top cover plate (19) from the pinion with the help of knurling provided on Top Cover Plate. It may be necessary to pry gently with a screwdriver. c) Remove the top cover plate O ring (20) and discard, if replacing soft parts. 5.2.3) Removal of Stroke Adjustment Bolts (12) ( Figure 6):
a) Remove the end cap bolts (15) in the sequence shown in the figure 7.
Caution!: When disassembling a spring return actuator, the end cap (02,03) should be loose after unscrewing end cap bolts (15) 4-5 turns. If there is still force on the end cap bolt (15), this may indicate a damaged spring cartridge and any further disassembly should be discontinued. Further disassembly of the end caps may result in serious personal injury. Return the actuator to Virgo for further
b) For spring return actuators, remove spring cartridges (26). c) Remove end cap O rings (24) and discard if replacing all soft parts. 5.2.5) Piston (04) Disassembly (Figure 8):
a) Remove both the Stroke Adjustment Bolts (12) together with nut (13) and washer (14). Replace the Stroke Adjustment Bolts (12) in case of excessive wear observed on the bolt surface.

a) Remove the circlip (25) using a circlip plier. b) Remove the cam rotating washer(31), cam (11), cam bearing (10). It may be necessary to pry gently to cam with a screwdriver. Observe the cam surfaces for excessive wear, where the Stroke adjustment bolts are resting and the cam ID (Square c/s). Replace the cam, if excessive wear is observed. c) Apply a downward force to top of the pinion (05) so that the pinion will move completely out of the bottom of the body (01). If the Pinion (05) does not move freely, gently tap with a plastic mallet. d) Remove the top and bottom bearings (08,09) and top and bottom O rings (21,22). Discard if replacing all soft parts. 5.2.7) Cleaning and inspection:
a) Hold the body (01) in a vice or similar device. Rotate the pinion (05) until the pistons (04) reach the end positions (i.e. the piston rack teeth disengages with pinion teeth).
Caution!: Air pressure should not be used to remove the pistons from the body.
When all components are disassembled, those not being replaced should be properly cleaned and inspected for wear prior to re-assembly. 5.3 Assembly: Prior to assembly, ensure that all components are clean and undamaged. It is recommended to use the lubricants as mentioned in Table 2. Table 2: Recommended Lubricants General Use 5.3.1) CASTROL GREASE - AP3
Clean and inspect the piston teeth for signs of wear. Replace pistons, if wear seems excessive. b) Remove piston O rings (23), piston guide band (07). Discard the O rings and guide band, if replacing the soft parts. 5.2.6) Removal of Pinion (05), Cam (11) and bearings (08,09) (Figure 9) :
Pinion (05) Assembly (Figure 10) :
a) Install the top and bottom bearings (08,09) and O rings (21,22) onto the pinion (05). b) Apply grease to the pinion bearings (08,09), shaft O rings (21,22) using general-purpose grease listed in table 2.

d) To ensure that the piston (04) teeth are evenly engaged, fully compress both the pistons inward and measure the distance from the edge of the body to the piston (04) face on each side, shown as dimension A in figure 13. If a different value is obtained on each side, remove the pistons and repeat from step 2c.
c) Insert the pinion (05) into the body (01) from the bottom side. Ensure that bottom surface of the pinion should be around 0.5mm inside the body bottom face and the pinion top slot orientation is as shown in figure 11. 5.3.2) Piston (04) Assembly (Figure 12 & 13): e) Temporarily install the local position indicator (28) onto the pinion (05) to determine whether the correct stroke is obtained. Ensure that the arrow in the local position indicator (28) will rotate a minimum of 5 beyond the 90 vertical centerline of the actuator body (01) and a minimum of 5 beyond the 0 horizontal centerline of the actuator body as shown in figure 14. If the proper stroke is not obtained, remove the pistons and repeat from step 2c. Once proper stroke is obtained, remove the local position indicator (28).
a) Fit piston pad (06), piston guide band (07), piston o-rings (23) on the pistons (04). b) Apply grease to the internal bore of the body (01) & to the piston rack teeth using recommended general - purpose grease listed in table 2.
c) Press the two pistons simultaneously in the body bore until the pinion racks are engaged and rotate the pinion until the stroke is completed. Take care that the pistons are oriented correctly as per the fail position of the actuator (The standard fail action of actuator is fail clockwise). Refer Fig 12 & Fig 13.

For spring return actuator, insert the proper quantity of the spring cartridges (26) according to the pattern shown in Fig 16 (referring to the total number of springs). Insert the spring cartridges (26) as shown in Fig 17. Apply grease to the end cap O rings (24). Fit the O rings (24) into the groove in each end cap (02,03). Fit the Plug Transfer port (30) inside the body (01) on each side. Fit the end caps. Insert all the end cap bolts (15) and hand tighten. Complete tightening by following the sequence indicated in Fig 18.
5.3.3)
Cam (11) Assembly (Figure 15):
DOUBLE ACTING ACTUATORS. Apply grease to the end cap O rings (24). Fit the O rings (24) into the groove in each end cap (02,03). Fit the Plug Transfer port (30) inside the body (01) on each side. Fit the end caps (02,03) onto the body (01), verifying that the O rings (24) remain in the groove. Insert all the end cap bolts (15) and hand tighten. Complete tightening by following the sequence indicated in Fig 18.
a) Insert the cam bearing (10) and cam (11). Ensure that the cam orientation is as shown in the figure 15. b) Insert the circlip (25) using the circlip plier.
SPRING RETURN ACTUATORS.

5.3.6) 5.3.4) Assembly of Stroke Adjustment Bolts (12) a) Insert the nut (13), washer (14) onto the stroke adjustment bolt. b) Screw in the bolts (12) into the body (01). 5.3.5) External Travel Stop Adjustment (Figure 19) : The stroke adjustment bolt to the right controls the clockwise end of travel, while to the left controls the counter-clockwise end of travel. Cycle the actuator to the clockwise end of travel and determine if the pinion top slot is in the proper position (In most of the applications this will be perpendicular to the actuator body i.e. at 900) If the pinion top slot is not in the correct position, turn the right stop adjustment bolt (12) IN to reduce actuator travel, or OUT to increase actuator travel. When the correct clockwise position is obtained, hold the adjusting bolt (12) stationary while tightening the nut (13). Cycle the actuator to the counter-clockwise end of travel and measure to determine if the pinion top slot is in the proper position. (In most of the applications, this will be parallel to the actuator body i.e. at 00 ). If the pinion top slot is not in the correct counterclockwise position, turn the left stop adjustment bolt (12) IN to reduce actuator travel, or OUT to increase actuator travel. When the correct counter-clockwise position is obtained, hold the adjusting bolt (12) stationary while tightening the nut (13). Top Cover Plate Assembly (Figure no 20):
Paste the top cover plate gasket (18) to the top cover plate (19) by using suitable paste/solution. Fit the O ring (20) using grease inside the top cover plate. Insert the top cover plate (19) onto the pinion (05). Fit the three counter sunk screws (17) on the cover plate.
a)
5.3.7) Local Position indicator Assembly (Figure no 21): Fit local position indicator (28) assembly onto the pinion (05). Ensure that it indicates the correct Actuator position. Tighten the counter sunk screw (29) to secure the local position indicator.
b)
c) d)
5.3.8) Actuator Lock Out Arrangement : For 052-100 Models (Refer to fig no-23 & 24): To lock the actuator at fully closed condition, cycle the actuator to clockwise end of travel, till the counter on the cam is inline with backside tapping. Rotate the right stroke adjustment bolt OUT & left stroke adjustment bolt completely IN. (Refer to fig No-23) To lock the actuator at fully opened condition, cycle the actuator to counter clockwise end of travel. Rotate the left stroke adjustment bolt OUT & right stroke adjustment bolt completely IN. (Refer to fig No-24) For 115-270 Models (Refer to fig no-25 & 26): To lock the actuator at fully closed condition, cycle the actuator to clockwise end of travel, till the counter on the cam is inline with backside tapping. Rotate the right stroke adjustment bolt OUT. Insert the locking bolt from backside as shown in fig no 25. To lock the actuator at fully open condition, cycle the actuator to counter clockwise end of travel, till the counter on the cam is inline with backside tapping. Rotate the left stroke adjustment bolt OUT. Insert the locking bolt from backside as shown in fig no 26.
e)
f)

Please follow above orientation for serrated insert and local position indicator as per your requirements. 5.4.1. Disassembly of Inserts: 1) Mount appropriate insert removing tool (33) on rod (35) as shown in figure. (e.g. For Insert 30x22 Double D, select insert removing tool of marking 30x22 ). 2) Guide insert removing tool (33) in cavity of insert (32) (e.g. double D ) as shown in figure 29. 3) Turn insert removing tool by 90o through rod (35) and blow hammer (34) upward / direction shown in figure (29). 4) Insert (32) will come out from pinion serration after hammer blow. 5.4.2. Assembly of Insert on Pinion: 1) As per final output drive requirement, match the insert (32) on pinion serration (05). Two dots are provided on insert(32) & one on pinion (05) so that one can perfectly match Double D, Square drive properly. See fig. 27 (a), (b) & fig. 28 (a), (b). 2) For diagonal square drive, make inserts (32) square diagonal i.e. diagonal of square & actuator axis should be inline. See fig. 27 (b). 3) After matching required output drive, hammer insert by rubber mallet (not shown in figure).
5.4 Mounting of Insert : Following procedure gives
guidelines for assembly / disassembly of serrated pinion and serrated inserts.

a) b) Drive By Square Head : refer fig. 27 (a) & (b). Drive By Double D / Flat Head: Refer Fig. 28 (a) & (b). (Reference Standard: DIN EN ISO 5211).

6. Storage : All the Virgo 2V actuators are factory lubricated for one million cycles under normal operating conditions. The ports are plugged to prevent material from entering the actuator during the shipment. If the actuators are not for immediate use, the following precautions must be taken during storage. a) Store in a dry environment. b) It is recommended that the actuator be stored in its original box. c) Do not remove the plastic plugs on the air supply ports.
6.
Trouble shooting:
A) Valve not operating: 1 Confirm specified air pressure is supplied to actuator for which actuator is sized/selected. Refer tag plate. 2 Increase air pressure by 1-1.5 KG/cm2 than specified . Observe the performance. If valve operates at this increased pressure, valve servicing is required. 3 If still valve does not operate, isolate actuator from valve. Connect air & observe performance of actuator independantly. If actuator strokes, valve servicing is required. 4 If isolated actuator does not operate, call / report to M/S VELs service cell for actuator rectification. B) 1) 2) Valve got struck: Bypass all accessories like solenoid, positioner quick exhaust valve, speed control valve & apply air direct to actuator ports. If valve/actuator operates, re-assemble accessories one by one & go on testing. Try to locate defective accessory & replace it. If actuator does not stroke even after applying air directly, isolate it from valve. Try to operate valve 2-3 times manually. Re-install actuator. Apply air pressure (higher than specified). Now if actuator strokes, valve servicing is required & if not report to M/S VEL.
C) Actuator does not stroke fully/Actuator operation found sluggish: 1) Even after isolating actuator from valve & applying excess pressure, if this observation persists, check for air bleeding from the port B, between body-End cap joint, between stroke bolt-end cap.
Important! If such leakages are observed, actuator torque output will be reduced and valve will not operate. Replace all seals with new one
2) Ensure grease inside actuator is not contaminated with moisture or water. Clean actuator inside & re-grease it. 3) If still actuator performance is not improved, report to VEL. WARNING! M/S VEL does not take any responsibility, if in case it is found that the actuator is damaged in attempting to dis-assemble it at Customers end.
10

D:\1483\My Documents\My Documents\IOM FOR Printing Revised\2V SERIES.doc
11

Seal Kit consist of:- Item No. 20, 21, 22, 23, 24. Repair Kit consist of:- Item No. 06, 07, 08, 09, 10, 18, 20, 21, 22, 23, 24, 25, 30.
D:\1483\My Documents\My Documents\IOM FOR Printing Revised\2V SERIES.doc
12

HEAVY DUTY ACTUATORS
1. General:
This manual contains the important information regarding the installation, operation and troubleshooting of the Heavy Duty Actuators pneumatic actuators. Please read these instructions carefully before operating the actuator. Warnings! : It is important that the actuator should only be used within the pressure limits indicated in our technical specifications. Operating the actuator over pressure limits will damage internal parts as well as cause damage to the the housing. Operating the actuator over temperature limits will damage internal and external components (disassembly of spring return actuator may become dangerous). Operating the actuator in corrosive environments with incorrect protection may damage the internal and external parts. Do not disassemble the spring cartridges. Disassembly may result in personal injury. Isolate all airlines and make sure that actuator air connection is vented before installation or servicing of actuator. Do not remove end caps or disassemble the actuator while the actuator is pressurized. Before installing onto a valve, make sure that the rotation of the valve and the actuator are the same and that the position indicator orientation is also correct. If the actuator is in a system or used within safety devices or circuits, the customer shall ensure that the national and local safety laws and regulations are observed.
possible to change this style of operation. If the spring return actuator is not set up in the configuration desired, follow the disassembly procedure section 6.1. Reverse the orientation of the yoke, then reassemble following the assembly procedure, section 6.2. 2. Mount the actuator to the valve as per the desired orientation (parallel or perpendicular to the pipeline). 3. Connect a regulated air supply to the NPT fitting in the actuator housing.
Caution! : The maximum operating pressure is 100 Psi (7 bar).
4. Adjust the stroke adjustment bolts following section 15. Stroke adjustment bolts can be adjusted by up to +5 on both directions. 4. Operation: The Heavy Duty Actuator actuators have simple operational characteristics. Operation is done by supplying air through two ports. Port B (facing the ports and reading right to left) is connected to the interior cavity between the pistons directing the airflow into/out of the interior cavity. Port A is connected to the end cap cavities directing airflow into/out of the end cap area. 4.1 Double Acting (Figure 1): Air supplied through port A forces the piston, causing the yoke to rotate counter clockwise (with exhaust air exiting through port B). Air introduced through port B forces the piston, causing the yoke to rotate clockwise (with exhaust air exiting through port A).
2. Technical Data: Operating Media: Dry or lubricated air, noncorrosive and inert gas or light hydraulic oil. Air Supply: 7 bar (100 Psi) Maximum. Temperature: Standard: -4 F to 175F (-20C to 80C) Viton O Rings: -4 F to 300F (-20C to 150C) Silicon O Rings: -40 F to 175F (-40C to 80C) Lubrication: Factory lubricated for the life of the actuator under normal conditions. Construction: Suitable for indoor and outdoor use. External Travel Stops: +5 (On Both Directions) adjustment on 90 stroke. 3. Installation: 1. Ensure that the desired failure mode is correct (Refer to figure no. 1,2 & 3). The Heavy Duty Actuator actuator typically operates counter clockwise to open and clockwise to close, it is
4.2 Spring Return:

Fail Clockwise (FCW) (Standard Scope of Supply) (Figure 2): Air introduced through port A forces the piston away, compressing springs and causing the yoke to rotate counter clockwise (with exhaust air exiting through port B). Upon loss /release of air pressure, springs forces the piston towards original position causing yoke to rotate clockwise (FCW) (with exhaust air exiting through port A).

HEAVY DUTY ACTUATORS b) Remove spring cartridge Assembly (44) from piston rod (25). 3) Removal of Adapter Plate: a) Remove all adapter plate bolts (40). b) Remove adapter plate (27) from actuator body (01). 4) Removal of Piston Rod : a) Remove all housing cover screw (06). b) Remove housing cover (07) with housing cover gasket (20) from actuator body. c) Remove yoke pin circlip (06) and housing roller (21) from yoke pin. d) Remove yoke pin (04) from piston rod (25) and yoke (03). e) Remove piston rod from actuator housing (01). 5) Removal of Torque Shaft :
4.2.2 Fail Counter Clockwise (FCCW) (Figure 3): Air introduced through port A forces the piston away, compressing springs and causing the Yoke to rotate clockwise (with exhaust air exiting through port B). Upon loss /release of air pressure, springs forces the piston towards original position causing yoke to rotate counter clockwise (FCCW) (with exhaust air exiting through port A).
PORT A
PORT B
5 Maintenance: 5.1 General: Heavy Duty Actuator actuator is supplied with Metric fasteners. Under normal operating conditions, the actuator requires only periodic observation to ensure proper adjustment. Service kits are available to replace seals and bearings (soft parts). These parts are identified in Figure 10 and listed in Table 9.Consult factory for repair Kits.
a) Remove Open and close indication tag plate (47) & (48). b) For removal of bearing retaining plate (12), remove all bearing retaining screw (13). c) Remove the needle bearing (11) and bearing housing (10) d) Slightly tap with a mallet on the Yoke key (18) to free it from yoke and torque shaft assembly. remove the torque shaft (19).
FIG.4
6 Disassembly and Assembly Instructions :

6.1 Disassembly Instructions: ( Refer to exploded view No. 10) When disassembly of the actuator is required for maintenance, remove the actuator from the valve. Ensure proper lifting procedures are followed when moving or carrying actuators. When disassembling the Heavy Duty Actuator actuators, use caution and be certain that the actuator is free from accessories and the air supply is disconnected. When the actuator is a spring-return unit, make sure that the actuator is in the failed position before disassembling. 1) Removal of Piston : a) Remove tie rod lock nut (33) and tie rod (32). b) Remove endcap (34) from pneumatic cylinder. c) Remove pneumatic cylinder (28) d) Remove piston bolt (30). e) Remove piston (29) from piston rod (25). 2) Removal of Spring Cartridge Assembly: a) Remove all spring cartridge studs (41) and nuts (42).

HEAVY DUTY ACTUATORS FIG. 5 5. Fit the piston to the piston rod using the piston Bolts (30). 6. Slide the cylinder over the piston and using the tie rods, tie rod lock nuts and endcap clamp the cylinder to housing (Fig 6). 7. Insert the torque shaft and fit it into the yoke (03) using yoke key (18). 8. Insert the needle bearings with bearing housings. Secure them with bearing retainer and retainer screws. 9. Cover the housing using housing cover gasket (20), housing cover screws (08). 10. Attach the open close indication plates.
SPRING RETURN ACTUATORS :

11. Insert the spring cartridge (44) on to the piston rod taking care so as not to damage the piston rod and clamp the spring cartridge to the housing using cartridge studs (41) , nuts (42) and sprin washer (43) Note: Support the spring cartridge during assembly on to piston rod to prevent the damage to the piston rod.
FIG. 6
DOUBLE ACTING ACTUATORS:

12. Insert the rod cover (44) on to the piston rod taking care not to damage the piston rod. Secure the rod cover using lock washers (43) and rod cover bolts (41). 6.2 Assembly Procedures : The following procedure describes the assembly procedure for heavy-duty actuators. 1. Clean all the components and apply grease on them. 2. Fit the Piston rod bearings (02), Needle bearings (11) with bearing Housings (01) in the piston rod bores and Torque shaft bores of the Housing (10) respectively. 3. Insert the yoke (03) in to the Housing (01). And centre the yoke in the mid or 45o position as shown in the Fig. 5 It is recommended to use the lubricants as mentioned below. General Use : CASTROL GREASE - AP3 4. Insert the piston rod (25) and assemble piston rod with yoke using yoke pin (04) & yolk rollers (05) Fig 5. Use circlips (06) to retain the yolk pin in its position. 13. External Travel Stop Adjustment: The Stroke Adjustment Bolt to the right controls the clockwise end of travel, while to the left controls the counter-clockwise end of travel. Cycle the actuator/valve to the clockwise end of travel and measure to determine if the valve is in the proper position. (In most of the applications, this will be fully closed) If the valve is not in the correct clockwise position, turn the right stop adjustment bolt (15) IN to reduce actuator travel, or OUT to increase actuator travel. When the correct clockwise position is obtained, hold the adjusting bolt (15) stationary while tightening the nut (16). Cycle the actuator/valve to the counter-clockwise end of travel and measure to determine if the valve is in the proper position. (In most of the applications, this will be fully opened). If the valve is not in the correct counter-clockwise position, turn the left stop adjustment bolt (15) IN to reduce actuator travel, or OUT to increase actuator travel. When the correct counterclockwise position is obtained, hold the adjusting bolt (15) stationary while tightening the nut (16). 3

7. Cleaning and inspection:

When all components are disassembled, those not being replaced should be properly cleaned and inspected for wear prior to re-assembly. PROPER LUBRICATION TO BE DONE PRIOR TO ASSMEBLY.
8. Storage
All the Heavy Duty Actuators are factory lubricated. The ports are plugged to prevent material from entering the actuator during the shipment. If the actuators are not for immediate use, the following precautions must be taken during storage. a) Store in a dry environment. b) It is recommended that the actuator be stored in its original box. c) Do not remove the plastic plugs on the air supply ports.

9. Part List

10. EXPLODED VEIW

DECLUTCHABLE MANUAL OVER-RIDE M: 1 INSTALLATION: The Rotary Manual Over-ride mounts in between valve and actuator. These are available in three models: RM-1, RM-2, RM-3. Selection of a model is based on total torque of valve and actuator combination. 1. Before installation ensure that: Coupling for valve to gear box and gear box to actuator are of proper fit. Keys to be used for engagement are of proper dimensions. Coupling surface are smooth and slide easily in and out of sector gear. If required file /grind surfaces lightly. Sector gear movement accommodates entire valve rotation / travel. Valve is in fail safe position. Following hardware is available For RM-1: M8/10x20 S.S.Hexbolt-8 No. RM-2: M16x25 S.S. Hexbolt-8 No. RM-3: M20x30 S.S. Hexbolt-8 No. Spring washers of relative size. 2. Before installation, operate gearbox (MOR) to ensure the direction of rotation of sector gear matches with the valve rotation (CW to Close/CCW to Open). 3. Mount bracket and coupling on the valve. Place gear box on valve coupling. The standard practice is to position the gearbox with its hand wheel parallel to pipe line and from port face of actuator. 4. Align the slots on sector gear and coupling. Insert key for engaging coupling to sector gear. 5. Match the holes and insert bolts. Keep the bolts finger -tight. For matching holes, if required rotate gearbox housing a few degrees through hand wheel. Refer # M 2.1, to engage MOR for its operation through hand wheel. 6. Mount bracket over gearbox and bolt it. Keep the bolts finger tight. Slide coupling over the key to engage with sector gear. 7. Lower the actuator on coupling until it rest over the bracket surface. 8. Match the holes, if required flow step # 5 and insert bolts. 9. Further tighten all mounting bolts. Operate valve 2-3 time manually-with gearbox to ensure sector gear movement accommodates the entire valve travel from full open to close position. 10. Declutch the gearbox. Refer # M: 2.2. Stroke actuator pneumatically 2-3 times to allow selfalignment of couplings. Tighten all mounting bolts fully to avoid the relative movement between actuator to MOR and MOR to valve. Adjust actuator piston stroke at this time.
M:2 OPERATION:
Manual over-ride operates on Worm-Worm Wheel Mechanism. Multiturns of hand Wheel / Worm shaft rotates Worm Wheel / Sector Gear through Quarter turn. Worm shaft is secured by means of Eccentric bushes at its ends. 180 rotation (Half turn) of Eccentric Bushes shifts the worm shaft towards or away from the worm wheel / sector gear to Clutch / Declutch. Refer the following instruction to clutch / declutch the MOR. M: 2.1 MOR in Engaged Mode / Manual Mode: MOR can be engaged at any position over the entire valve travel- Close /Open / Intermediate.
CAUTION! Before engaging MOR, cut off air supply to actuator to ensure that the manual force through gearbox is not acting against pneumatic pressure.
Lift Lock Pin momentarily and rotate declutch Lever a few degree to dislodge the pin tip from its seat / pin hole on Eccentric bush. Release the lock pin and it will remain floating. Further rotate declutch lever CW (towards actuator) through 180 until the spring loaded lock pin drop down. Rotating lever CCW in this mode defeats the purpose. Worm shaft is now engaged with sector gear.
CAUTION! Never apply excessive force to lift lock pin and to rotate declutch lever. This may damage either of lock pin or Eccentric bush permanently.
To make the declutch lever movement free and easy; it may be necessary to turn the hand wheel slightly to mesh the gears. Rotate the hand wheel CW / CCW to open / close valve (Refer direction arrow on hand wheel). Important! Before returning to pneumatic operation always declutch MOR. M: 2.2 MOR in Declutched Mode: WARNING!: Never declutch MOR against spring force acting through actuator i.e. if a valve with MOR

DECLUTCHABLE MANUAL OVER-RIDE & spring return actuator is operated manually to open (Fail to Close) the valve, do not try to declutch MOR in this condition. Attempting the same may lead to personnel injury or damages to MOR. Lift the Lock pin and rotate Cl. / Declutch Lever CCW (towards Valve) through 180 until the spring loaded lock pin drop down. Rotating lever CW in this mode defeats the purpose. Confirm hand wheel rotates freely. Connect air supply to actuator. not smooth, dis-assemble and lubricate with grease. After certain clutch / declutch operations adjust length of pin tip protruding out of its housing to ensure positive locking of pin with worm shaft. M: 4 TROUBLESHOOTING: Actuator does not stroke MOR is in engaged mode, Declutch it. Ensure sector gear is engaged with coupling to actuator. Valve does not operate manually through MOR: Confirm MOR is in engaged mode and sector gear is engaged with valve coupling. Confirm air supply to actuator is disconnected. Cl./Declutch lever does not rotate freely, MOR does not clutch / declutch: Lift the lockpin. Rotate handwheel slightly to mesh the gears and rotate the levers simultaneously to clutch / declutch MOR. Ensure pin locks positively with worm shaft. If pin tip is damaged, replace it. M: 5 LIST OF RECOMMENDED SPARES: 1. Lock pin assembly 2. Cl./declutch lever. 3. Seal kit (consists of a pair of bush bearings, o-rings to sector gear, worm shaft, eccentric bushes) please specify MOR model while ordering spares. Please specify MOR model while ordering.
M: 2.3 Changing Fail Safe Condition of Valve / Orientation of Manual Override:

To meet above requirements, it is necessary to dis-assembly gearbox unit to reposition the sector gear. In continuation to IOM Instruction for actuator 4.3 refer the following instructions to change fail safe condition of the valve assembly with VALVE + MOR +Actuator. 1. After changing fail safe condition of valve, there are chances of mismatch of valve coupling of keyway and sector gear keyway by 90. 2. Also the direction of rotation of valve, from close to open or vice versa may get reversed. 3. Under such conditions, disassemble gear box housing by removing cap screws 08 nos. 4. Remove sector gear and reverse it up side down. This will shift the key way position. If required further rotate sector gear by 90 to ensure the alignment of key ways. 5. Operate hand wheel to ensure the rotation of sector gear accommodates the new valve travel as well as key ways on sector gear get aligned at both valve positions. 6. Re-assemble the housing. Follow # M: 1 INSTALLATION to re-install the manual Override. Operate valve + MOR manually 2-3 time to re-assure the valve operation (opening / closing) meets the new requirement. M: 3 MAINTENANCE: The manual over rides are designed for long life and trouble free operation. User must attend the following points to ensure smooth, trouble free & maintenance free operation over a prolonged period. The self locking pin locks and unlock just with momentary lift and worm shaft rotate by 180 in CW / CCW smoothly using declutched lever. MOR operates smoothly and the desired valve position is achieved by rotating the hand wheel. Check for smooth operation of valve when MOR is declutched. If the operation of MOR is

DECLUTCHABLE MANUAL OVER-RIDE
PARTS & MATERIALS GEAR BOX ASSEMBLY MODEL- RM1 / RM2

Description Body casing- Top & Bottom Body Fastners Dowel Pins Sector Gear Assembly: Sector Gear Nylon Bush & O-Ring- Top & Bottom Lock Pin Assembly: Lock Pin Spring Adjuster Nut & Bolt Lock Pin Holder 20 19 7,8 21 5 3,4 Part No. 6,1 9,2 23 Description Worm Shaft Assembly: Worm Shaft O-Ring Eccentric Bushes -with collar on hand wheel side - Rear Side Ecc.Bush Connecting rod Cl./Declutch Lever Ny. Bush & O-rings to Ecc. bush Handwheel: Direction Indicating / Covering plate Handwheel Retaining Bolt 13 24 15 11 14 22 12,10 25 16,18 17 Part No.

LIMIT SWITCH BOX.
Limit Switch Box: The automated control valve is provided with limit switch Box mounted on the top of actuator. Limit switch box facilitates remote as well as local indication of valve position. L: 1 INSTALLATION: Installation of Limit switch box on actuator is best performed using standard bracket for actuators with Namur mountings & with customized bracket/couplings for actuators without Namur mounting. Mounting: Fix the housing to the bracket(M8 X 12 SS Hexbolts-4 nos) Additional coupling is not required for actuators with Namur mounting. As the bottom side of the shaft is designed to NAMUR standards, engage it directly with pinion. Bolt the bracket on top of actuator (M5 x 12 S.S. Hex-4 nos) for Non-Namur actuators use coupling to engage Switch Box shaft with actuator pinion. Bolt the bracket on top of actuator(M5 X 12 SS Hexbolts 4 nos) Fix all the bolt and tighten them evenly. Ensure bracket faces are resting properly on actuator top and there is no building of stresses on coupling or shaft. Confirm the local indication (Open / Close) on pharos indicator match to that of valve position. Insert the cable through cable gland and connect it to the terminal strip. (Refer Wiring Diagram). The switch box is provided with two cable entries( third one is optional & can be provided on demand), if only one cable entry is to be used, plug the other properly
IOM/LS/ATEX/06/REV.0

LIMIT SWITCH BOX. Confirm the changeover of switch contact with multimeter by stroking actuator 2-3 times. The cams are provided to activate the switches at 0 & 90 valve travel but can be adjusted to indicate any position between 0 and 90 valve travel. L: 2.2 PHAROS VISUAL POSITION INDICATOR ADJUSTMENT: 1. Note Valve/actuator position before starting. 2. Loosen the screws on clamping ring & match the open/close position windows on inner & outer dome. 3. Tighten the screws on clamping ring to fix open/close position. 4. If dome window still does not line up, repeat steps #2-3. 5. For best visibility, wipe dome periodically with a damp non-abrasive cloth. L: 2 OPERATIONS: L: 2.1 Switch Setting The switch box encloses limit switches/sensors, (no.of limit switches varies with application & customer requirement), prewired to terminal strip. The switch are pre-set to indicate Open and Close valve position. Bottom switch indicates Close position while top switch indicates Open position of valve. Before setting switches, isolate electric supply and remove top cover of switch box. To remove top cover loosen the four screws on clamping ring. Then remove clamping ring & then outer dome. Now remove inner dome which is engaged with stem. Rotate the top cover by hand in anticlockwise direction till it gets free from housing. With top cover removed, there will be clear access to cam & limit switches. Bottom Switch Setting: Lift the lower cam to disengage the splines and turn it CW until the switch is activated (i.e. electro mechanical switch should be pressed fully or proximity sensors should be activated to complete the circuit- in some models, inbuilt LED glows ON when sensor is activated.) Release the cam and make sure it will engage with the splines. Top Switch Setting: Stroke the actuator to full CCW position. Depress the upper cam to disngage the splines and turn it CCW until the switch is activated. Release the cam. Caution! Never apply excessive force to engage / dis-engage cams, this may damage cam / gear permanently IOM/LS/ATEX/06/REV.0
CAUTION! Some acids, caustics and hydrocarbons can discolor or cause stress revealing damage. L: 2.3 Switch Options: A. Electro Mechanical Switches ------------------------------------------------------------------Switch Type Switch Chararacteristics Qty. ------------------------------------------------------------------V-5 SPDT-10A/250VAC 2-NSW - 0.5A/125VDC 4-LSW -0.25A/250VDC B. Namur Proximity Switch (Intrinsically Safe): ------------------------------------------------------------------Switch Type Switch Chararacteristics Qty ------------------------------------------------------------------SJ3,5-N Slot type. 2 Wire, 2 NJ2-V3-N Rect.type,2 Wire, 2
Apart from above, other switch options can be provided as per customers requirement. L: 3 TROUBLESHOOTING : The limit switch box is designed to provide trouble free / maintenance free service. However the following probable causes and solutions may help the user to sort out the typical problem faced at commissioning stage: a. Switching operation not reliable: Operate / press switches (electro-mechanical) manually and check the contact changeover at switch terminal as well as at PCB terminal strip.

LIMIT SWITCH BOX. If switches are OK, set the cams properly to press switches fully. If contact changeover is not observed even by operating switches manually, replace the switches. b. Switch setting changes frequently: Confirm that gear on spindle are intact and there is no slippage between spindle and gear. If gears are damaged, replace the spindle assembly. c. Local indication is not proper / changes Frequently : Loosen the clamping ring. Match the window on inner & outer dome. Toghten the screws on clamping ring.
Precautions: a. Always close the top cover of enclosure by rotating it fully. b. Confirm O-ring to top cover, Outer dome is intact and placed properly. c. Plug the unused cable entry. d. Use cable of proper sheath / insulation thickness suitable for cable gland provided along with switch boxes. e. Never hammer pharos indicator cover. f. Insulate electric supply to limit switches before opening top cover. L: 4 LIST OF RECOMMENDED SPARES: Limit switches O-rings Local position indicator assembly
Note:- While ordering spares, please specify material of box, type and no. of limit switches provided.

LIMIT SWITCH BOX. LSW
H.O. & WORKS:
VIRGO ENGINEERS LIMITED Survey No. 277, Raisoni Industrial Park, Phase-2, Hinjewadi, Pune-57 Tel.: (020) 66744000, Fax : (020) 66744021 E-mail : virgo@virgoengineers.com Website : www.virgoengineers.com VIRGO VALVES & CONTROLS LIMITED Survey No. 277, Raisoni Industrial Park, Phase-2, Hinjewadi, Pune-57 Tel.: (020) 66744000, Fax : (020) 66744021 E-mail : valve@virgovalves.com Website : www.virgovalves.com
WORKS:
BRANCH OFFICES: MUMBAI 1001, 10TH FLOOR, KRISHNA GOVIND TOWERS, PLOT NO 22-26, SECTOR 24, VASHI, OPP. SANPADA RAILWAY STATION, NAVI MUMBAI-400 705. TEL (022) 27837757/56128510 FAX (022) 27837753 BARODA 14, GURUPRASAD SOCIETY, BEHIND AKOTA STADIUM, BARODA-390 015 TEL (0265) 2342837/2341053/2355133 FAX (0265) 2314449 KOLKATA 2-B, HARALAL DAS STREET SECOND FLOOR, ENTALLY KOLKATA-700 014 TEL (033) 22272269/22272533 FAX (033) 22272279 UAE BLDG-8, OFFICE NO 8G-19 P.O. BOX NO 41739 HAMARIYAN FREE ZONE-SHJ, UNITED ARAB EMIRATES TEL / FAX NO. 0097165741872 CHENNAI 59, GROUND FLOOR, TEACHERS COLONY KAMRAJ AVENUE, ADYARI, CHENNAI-600 020 TEL (044) 24404119/24414526 FAX (044) 24410664 DELHI 7/39, 2ND FLOOR, VIKRAM VIHAR, LAJPAT NAGAR-1V, NEW DELHI-110 024 TEL (011) 41729161 TO 41729164 FAX (011) 41729164 VIRGO ENGINEERS INC. 13219, N.PROMENADE BLVD, STAFFORD, TEXAS-77477 U.S.A., TEL 001-281-491-0400 FAX 001-281-491-0444

Installation, Operation & Maintenance Manual: Virgo Engineers Limited

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Installation, Operation & Maintenance Manual: Virgo Engineers Limited

Transféré par

Droits d'auteur :

Formats disponibles

Installation, Operation & Maintenance Manual

CUSTOMER CONSULTANT P.P. NO. & DATE DT. OF DESPATCH

VIRGO ENGINEERS LIMITED

REV. NO. PUBLISHED ON