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Operation & Maintenance Manual Model Aph Hydraulic Actuator
Operation & Maintenance Manual Model Aph Hydraulic Actuator
Operation & Maintenance Manual Model Aph Hydraulic Actuator
TABLE OF CONTENTS
I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II.
Actuator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III.
IV.
Actuator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V.
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VI.
VII.
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VIII.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IX.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
X.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
XI.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XII.
XIII.
XIV.
Sub-Assembly Operations
XV.
XVI.
XVII.
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XIX.
Field Removal and Replacement of Actuator Seal & Top Cylinder Seal . . . . . . . . . . . . 23
XX.
XXI.
XXII.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
page 2
INTRODUCTION
The Array model APH is a Hydraulic Actuator. This actuator is designed as a fail closed operator. The SSV APH
Hydraulic Actuator should be installed on the second valve and flow wing valve in the wellhead flow stream.
When two master valves are used, the SSV should be the top master valve. The SSV will be tested in accordance
with procedures given in the American Petroleum Institute specification 6A, latest revision. SSVs located in
federal waters should only be serviced by technicians that meet qualifications as defined by the Minerals
Management Service (MMS).
This installation and maintenance manual gives factory required assembly, disassembly and installation
procedures, trouble shooting and technical specifications.
Typical uses are for critical valve applications on wellhead production, drilling and exploration and pipelines.
ACTUATOR OPERATION
Array model APH Hydraulic Actuators are designed to operate Array Fail-Safe Bonnet Assemblies used on gate
valves and move them from their Fail-Safe positions. The thrust required to do this is created by application of
adequate control pressure to the actuator inlet port. Hydraulic pressure acting on the piston overcomes the
thrust created by the forces of the valve pressure acting on the bonnet stem and gate friction due to any pressure
differential acting on the valve gate and dual set of springs. It will open fail-closed gate valves. Removal of this
control pressure allows the bonnet stem forces to return the valve gate to its fail-safe position. The actuator
return spring provides the required force to overcome dynamic seal friction and the weight of moving parts
when no pressure exists in the valve.
When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft
will depend upon whether the valve is fail-closed and how much pressure differential is present across the
valve gate. Fail-closed valves will initially open with a sudden jerk as the gate cracks open and the pressure
differential is reduced. This is normal and does not damage the valve or hinder its function. The severity and
travel of this rapid motion depends on the amount of pressure differential across the valve gate. The greater the
differential, the more rapid the motion for a longer amount of the total valve stroke. The remainder of the
actuator motion should be smooth and uniform.
Upon removal of control pressure from actuators mounted on fail-closed valves, the motion should be smooth
throughout the entire stroke. Speed of this action depends on many factors such as how fast a differential
builds across the gate, is a locally mounted valve being used to exhaust the control pressure and the size of the
actuator and valve. As a general rule, the faster the control pressure is removed from the actuator the quicker
it will close.
The combination of compression spring assembly will provide approximately 1,750 to 2,000 pounds of force in
the closed position of the gate valve.
page 3
1.
2.
2M thru 15M
3.
BB
4.
5.
Performance Rating
PR-2
6.
Temperature Classification
7.
8.
9.
10.
Actuator Volume
11.
Weight
12.
Dimensions
page 4
ACTUATOR DIMENSIONS
page 5
MODEL
in
3
C
mm
18.00 457
in
mm
in
mm
10.36
263
5.40
137
in mm
in
2.00 50
mm
2.75 69
23.78 604
15.50
393
7.40
187
2.50 63
2.75 69
24.78 629
15.50
393
7.40
187
2.50 63
2.75 69
29.50 749
21.14
536.
10.12 257
2.50 63
2.75 69
30.50 774
21.14
536
10.12 257
2.50 63
2.75 69
31.50 800
21.14
536
10.12 257
2.50 63
2.75 69
32.50 825
21.14
536
10.12 257
2.50 63
2.75 69
33.50 850
21.14
536
10.12 257
2.50 63
2.75 69
37.65 956
27.10
688
12.96 329
2.75 69
2.75 69
38.65 981
27.10
688
12.96 329
2.75 69
2.75 69
39.65 1007
27.10
688
12.96 329
2.75 69
2.75 69
40.65 1032
27.10
688
12.96 329
2.75 69
2.75 69
B
C
MODEL
SWEPT VOLUME
CLOSING TIMES
WEIGHT
in3
cm3
seconds
lbs
kgs
9.5
156
24
46
21
11.0
180
35
46
21
19.0
311
24
112
51
22.0
361
35
112
51
26.0
426
46
117
53
31.0
508
57
117
53
39.0
639
79
129
59
34.0
557
13
279
127
40.0
587
35
279
127
46.0
675
46
284
129
54.0
793
57
284
129
69.0
1013
79
285
130
84.0
1233
911
276
125
98.0
1439
1012
281
128
150.0 2459
79
549
249
186.0 3049
911
552
251
218.0 3573
1012
560
254
253.0 4147
1113
562
255
ORDERING INFORMATION
The following information should be provided when requesting a quote or issuing a purchase order
to Array Products for an APH Actuator.
Actuator
Model of Actuator:_______________________________________________________________________________
Size of Actuator: ________________________________________________________________________________
Actuator Control Pressure Availability: ______________________________________________________________
Special Requirements:
Testing _______________________________________________________________________________________
Coating_______________________________________________________________________________________
Non-Rising Top Shaft ___________________________________________________________________________
Certification / Specification_______________________________________________________________________
Accessories
Fusible Lock Open Cap: __________________________________________________________________________
Fusible Manual Override: _________________________________________________________________________
Hydraulic Override: ______________________________________________________________________________
Stem Protector (Clear) (Metal):_____________________________________________________________________
Electronic Switches Proximity: ____________________________________________________________________
page 6
VALVE
BORE SIZE
3,000 PSI
5,000 PSI
10,000 PSI
15,000 PSI
11316
APH 25 x 020
4329 psi
.418 x wp + 149 psi
APH 035 x 020
2109 psi
.205 x wp + 59 psi
APH 045 x 020
1279 psi
.116 x wp + 119 psi
APH 025 x 020
APH 025 x 020
1334 psi
2124 psi
2116
.395 x wp + 149 psi
.395 x wp + 149 psi
2916
318
3116
4116
518
638
7116
Note: The designed values provided above only apply to actuators manufactured for Array gate valves and are provided for reference only. (SEE NOTES ON NEXT PAGE)
NOTE:
All actuator sizing complies with API 6A 10.16.3.7 (latest edition) force output valve requirements.
PSI is required pressure to crack valve @ maximum working pressure.
Sizing equation includes spring load.
PSI number is total of equation and spring load to open gate valve @ maximum working pressure.
Control pressure equation x valve working pressure + total spring load. When calculating control supply
for the APD use this equation.
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1. To select the proper actuator size and control pressure you must first determine the
gate valve bore size and the maximum working pressure of the valve.
2. Now determine the maximum flowing and shut in pressure for production.
3. Determine the available hydraulic control supply pressure at location.
4. Using the appropriate gate valve bore chart, find the y-axis location and draw a vertical line to the top of the chart.
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5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point defines the minimum
required actuator control pressure to open the gate valve.
Example: A valve pressure of 8,400 psi requires an actuator hydraulic control pressure of 2,824 psi to open gate valve
(APH 045 x 040). See control pressure equation on pages 7 & 8.
PARTS LIST
page 14
#
DESCRIPTION
Top Shaft
Piston
10
11
12
Cylinder
13
14
15
Bolt
16
17
Stem Nut
18
19
20
21
Inner Spring
22
Housing
23
24
Bonnet Ring
25
Burst Disc
26
27
Nameplate (NS)
28
29
Washers
8
11
7
5
9
3
10
2
25
4
6
12
18
19
20
30
32
Bonnet Stem
31
Drift Shims
32
Packing Retainer
33
O-Ring (BK)
34
O-Ring (BK)
35
36
Bonnet
37
Test Fitting
38
Nameplate (NS)
39
14
16
17
23
21
22
24
BONNET
30
13
31
33
34
14
13
35
29
15
36
Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves manufactured by companies other than
Array Products. In those cases the specific differences are usually limited to the design of the bottom of the bonnet and operating stem.
37
page 15
page 16
page 17
PROCEDURE
1. Examine the (Packing Retainer #32). Verify that bore threads are
clean and in good condition and o-ring grooves are clean and in
good condition.
2. Thoroughly clean the (Packing Retainer #32), removing all foreign
debris from thethreads and o-ring grooves.
3. Thoroughly lubricate the entire part with assembly lubricant and
then set aside.
4. Examine the (Bonnet #36). Verify that bore and threads are clean
and in good condition.
5. Thoroughly clean the Bonnet bore and O.D. threads and lightly
lubricate packing box with assembly lubricant.
6. Install the (Polypak Seal #35) in the bonnet packing box with the
packing o-ring energizer facing down. Push the packing rings down
to a positive stop.
7. Pick up the Packing Retainer and carefully thread the retainer into
the Bonnet with clockwise rotation to a positive stop. Tighten
retainer securely with a pipe wrench. Remove any metal shavings or
bits of residue from wrench operation.
8. Install a 1/2" (Test Fitting #37) in the tapped hole in the Bonnet
flange and tighten fitting securely. Use pipe tape or liquid (Teflon).
9. E
xamine the (Bonnet Stem #30). Verify that threads are clean and
in good condition, seal surface is clean and free of nicks, dings,
burrs and scratches.
10. Lightly lubricate the entire seal surface of the stem with
assembly lubricant.
11. Pick up the Bonnet and place it on its side.
12. Pick up the Stem and pass the Stem through the Bonnet and
packing set, from the flange side of the Bonnet until the Stem
backseat contacts its stop point. CAUTION: Be careful not to nick
I.D. sealing surface of packing by nose of bonnet stem.
Note: The design of the Stem/Gate connection will vary depending
on size, working pressure and manufacturer.
page 18
PROCEDURE
1. Push the (Bonnet Stem #30) down out of the (Bonnet #36) until the
stem end for gate adaptation is exposed.
2. Thread the gate onto the exposed portion of the stem in a closing
direction. Positiongate as required by valve manufacturers
installation procedure.
3. Rotate the gate slightly in either direction to align the slot in the
stem with the mating hole in the gate lift nut. Drive the pin
(supplied by the valve) through the gate pin hole in the stem slot.
4. Install new bonnet seal ring (supplied with the valve) in the valve
body and then carefully lower the gate into the valve body, between
the seats and allow the bonnet to pass over the valve body stud.
5. Install the valve body nuts on the studs and make up connection as
required by valve manufacturer.
6. The (Bonnet Stem #30) should slide easily upwards by pulling
the gate up to the fully closed position with your hands. The
(Stem Nut #17) can be threaded onto the stem for better leverage.
Do not use any other device or tool to lift the (Bonnet Stem #30)
to the fully closed position other than previously mentioned.
page 19
page 20
page 21
page 22
GATE
GATE
ADD SHIMS
REMOVE SHIMS
PROCEDURE
The following procedures should be followed in all cases of disassembling a production hydraulic actuator.
When replacing the actuator seals (2 each) from the cylinder follow these directions carefully.
1. Disconnect power source going to Actuator inlet. Be careful not to spill hydraulic fluid.
2. Do not disconnect the pressure relief device.
3. If a high pressure quick exhaust valve is used, disconnect from Actuator and set aside.
4. If electronic proximity switches are installed remove from top of cylinder. Do not injure or mishandle. Set aside.
5. If other accessories are mounted to the top of the Actuator remove and set aside. These accessories can be clear
stem protector, fusible manual override and fusible lock open cap. CAUTION: If a fusible lock open cap is installed
on the Actuator. Prior to any disassembly pressurize actuator to full open position to release upward thrust load
on cap. This operation will prevent injury to personnel and equipment. After pressurizing actuator unscrew
fusible cap and set aside.
page 23
page 24
PROCEDURE
The following procedure should be followed in all cases of disassembling a production hydraulic actuator. When
replacing bonnet packing seals the actuator must be removed from the bonnet assembly.
1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set
aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
6. Remove (Retainer Ring #11) from top to (Top Shaft Packing Retainer #7) in a counter clockwise direction.
CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is
noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged.
CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING!
7. Remove (Polypak #10) with extraction tool.
8. Replace with new (Polypak #10). Inspect sealing I.D. and O.D. with fingertips. Grease generously. Install
(Polypak #10) by pushing down into bore of (Cylinder #12). The o-ring energizer will face downward toward gate
valve when installed. Push until seal stops on shoulder.
9. Reinstall (Top Shaft Packing Retainer #7) by rotating in a clockwise manner until coming to a dead stop.
10. Install (Retainer Ring #11) into top of (Cylinder #12). CAUTION: Be sure to seat retainer ring into groove.
11. Reconnect all accessories to actuator and piping and valves to pressure entry port on actuator cylinder.
page 25
1. Using an adjustable wrench remove the four (Bolts #15) and (Washers #29) from the base of the Actuator
(Housing #22), set aside.
2. Remove (Housing Lock Ring #13) and (Housing Shear Ring #14), set aside. Leave on Bonnet.
3. Install two 3/4-10UNC-2A forged lifting eyes into side of (Cylinder #12)
5. With an overhead lifting device connect to the two lifting eyes and lift actuator off of the spring cartridge.
Set actuator down on clean, flat surface. Leave the two lifting eyes in place.
6. Using a large adjustable wrench, rotate (Spring Adjusting Nut #16) in counterclockwise direction. You are
relaxing the spring load from installed position to the free length position.
8. Remove (Upper Spring Plate #18), (Spring Guide Tube #19) and (Lower Spring Plate #20) from spring
assembly and set aside.
9. Lift (Inner Spring #21) off (Bonnet Ring #24) and set aside.
12. With (Bonnet Stem #30) back seated, rotate (Packing Retainer #32) in a counterclockwise direction. Use
a medium to large pipe wrench. CAUTION: Be careful not to nick the sealing surface O.D. of the (Bonnet
Stem #30). With the removal of the packing retainer a hissing noise may be evident indicating trapped
pressure and well condensate. Be very careful with eye and hand protection. Remove packing retainer,
lift off of bonnet stem and set aside.
13. Remove (Polypak Seal #35) four rings. Use pick to pull ring out of bore. Set old packing aside.
14. Grease packing bore generously. Install (Polypak Seal #35) with o-ring energizer facing down. Do not
use pointed or sharp objects to push packing down into bore. Set all four pieces of packing completely.
page 26
16. Install same number of (Drift Shims #31) onto packing retainer.
17.Check (Stem Nut #17) to insure that is fully threaded onto bonnet stem. Check (Socket Head Cap
Screws #6) for threaded engagement. They must be tight
18. Install the (Inner Spring #21) onto the (Bonnet Ring #24) springs are at free length position.
19. Place the (Upper Spring Plate #18) onto top of spring set, align spacing.
20. Insert (Spring Guide Tube #19) into bore of (Upper Spring Plate #18). Must shoulder properly.
21. Place (Lower Spring Plate #20). Down into bore of (Spring Guide Tube #19).
22. Thread (Spring Adjusting Nut #16) onto (Stem Nut #17) in a clockwise manner. Use a large adjustable
wrench to load the spring set. Continue rotation until (Stem Nut #17) stops on the (Spring Adjusting
Nut #16) shoulder. Note: the springs may rotate. This is normal and presents no cause for alarm.
23. Engage the two lifting eyes with the overhead lifting device. Lift the actuator over and down onto
(Bonnet Ring #24). The Actuator should stop correctly on the shoulder of the bonnet ring.
24. At the bottom of the Actuator install the (Housing Shear Ring #14). The ring must seat into the groove
and be tight.
25. Install the (Housing Lock Ring #13) into groove space. The ring cannot lock or wedge on the groove.
If this occurs remove both rings and clean housing groove and reinstall.
27. Remove lifting eyes from (Cylinder #12). Reconnect all accessories to actuator. Connect all piping and
valves securely to pressure entry port on actuator cylinder.
page 27
page 28
The burst assembly incorporates four (4) components. The body, cap, disc and disc seat. The following instructions
explain the correct method to replace the burst disc assembly.
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box/open end wrench, engage the hex wrench flats on the burst disc housing.
Using a second wrench (adjustable/open box) engage the hex flat on the burst disc cap. (Figure 1) Rotate the cap
in a counterclockwise direction until completely disengaged. (Figure 2) Remove disc seat and metallic particles of
exhausted disc. Clean inner bore and threads from burst disc housing. Install disc into bore. (Figure 3 & 4)
Caution: The convex surface of the disc must be facing outward at the installer. (Figure 5) Carefully inspect the
disc prior to installation. Make sure the contact surface of the body is clean for the disc to seal. Install the disc seat
on top of the disc center carefully. The disc seat can be installed from either side as it is symmetrical. (Figure 6)
Engage hex wrench flats on burst disc cap with an adjustable/open end wrench. Rotate the cap in a clockwise
direction. Tighten securely. (Figure 7)
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box open end wrench, engage the hex wrench flats on the burst disc housing.
Firmly, rotate the housing in a counterclockwise direction. Caution: Do not work over the housing during removal.
Remove housing from actuator. Clean all Teflon tape or liquid residue from internal and external threads before
replacement. Wrap Teflon tape in opposite direction to normal thread engagement around the threaded end of
the housing. Wrap securely. If Teflon liquid is used apply generously. Thread housing in actuator. Rotate in a
clockwise direction. The recommended torque for tightening the burst disc cap is 50 to 65 ft./lbs. The burst disc
assembly is ready for pressure service.
Figure 1
Figure 2
page 29
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
page 30
TESTING
page 31
1. The new assembled actuator will be tested per API 6A, latest edition. The following section applicable is 10.16.5.
a. Verify the following that all mechanical lock open devices are removed when proceeding with operational testing and back seat testing.
b. Hydrostatic testing of actuator, bonnet and gate valve may employ a mechanical override only.
NO LOCK CAPS ARE TO BE USED ON HYDROSTATIC.
c. Remove the pressure relief device from the actuator. After testing is complete the safety relief device
will be assembled to the actuator. Use a gauge or solid plug as a replacement.
d. In house testing will use hydraulic/nitrogen for functional testing. If problems arise during testing with
the actuator, disassemble. Repair and re-assemble.
PERIODIC MAINTENANCE
The following maintenance schedule is recommended to insure safe and reliable operation of the Array
Model APH Actuator.
MAINTENANCE OPERATION
Monthly
2.
Monthly
3.
Monthly
4.
Monthly
Monthly
1.
5.
INTERVAL
TROUBLESHOOTING
page 32
TROUBLE
ontrol Pressure in
C
Actuator Will Not Build
PROBABLE CAUSE
REMEDY
Inspect control line for damage and/or
leaking fittings
Insufficient pressure in
control line
Insufficient pressure in
control line
TROUBLESHOOTING
TROUBLE
Actuator Will Not Stroke
To Full Closed or Fail Safe
Close Position
page 33
PROBABLE CAUSE
REMEDY
ACTUATOR SPECIFICATIONS
Maximum Operating Pressure:
Test Pressure:
API Material Class:
API Temperature Rating:
API Performance Requirement:
Can be certified for Offshore SSV:
BONNET SPECIFICATIONS
Bonnets Available for Valve Brands:
Size Range Available:
Pressure Ranges Available:
API Material Classes Available:
PSL - 1, 2 or 3, Annex F
PR-1 or 2
L through X
Yes
2007 Array Holdings, Inc. All specifications and materials are subject to change without notice.
MODEL APHW
HYDRAULIC ACTUATOR
TABLE OF CONTENTS
I.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II.
Actuator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III.
IV.
Actuator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V.
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VI.
VII.
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VIII.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IX.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
X.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
XI.
Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XII.
XIII.
XIV.
Sub-Assembly Operations
XV.
XVI.
XVII.
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
XIX.
Field Removal and Replacement of Actuator Seal & Top Cylinder Seal . . . . . . . . . . . . 24
XX.
XXI.
XXII.
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
page 2
INTRODUCTION
The Array model APHW is a Hydraulic Wire Cutting Actuator. This actuator is designed as a fail closed operator.
The SSV APHW Hydraulic Wire cutting Actuator should be installed on the second valve in the wellhead flow
stream. When two master valves are used, the SSV should be the top master valve. The SSV will be tested in
accordance with procedures given in the American Petroleum Institute specification 6A, latest revision. SSVs
located in federal waters should only be serviced by technicians that meet qualifications as defined by the
Minerals Management Service (MMS).
This installation and maintenance manual gives factory required assembly, disassembly and installation
procedures, trouble shooting and technical specifications.
Typical uses are for critical valve applications on wellhead production, drilling and exploration and pipelines.
ACTUATOR OPERATION
Array model APHW Hydraulic Wire Cutting Actuators are designed to operate Array Fail-Safe Bonnet Assemblies
used on gate valves and move them from their Fail-Safe positions. The thrust required to do this is created by
application of adequate control pressure to the actuator inlet port. Hydraulic pressure acting on the piston
overcomes the thrust created by the forces of the valve pressure acting on the bonnet stem and gate friction due
to any pressure differential acting on the valve gate and dual set of springs. It will open fail-closed gate valves.
Removal of this control pressure allows the bonnet stem forces to return the valve gate to its fail-safe position.
The actuator return spring provides the required force to overcome dynamic seal friction and the weight of
moving parts when no pressure exists in the valve and shear a single diameter size cable or slick line wire.
When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft
will depend upon whether the valve is fail-closed and how much pressure differential is present across the
valve gate. Fail-closed valves will initially open with a sudden jerk as the gate cracks open and the pressure
differential is reduced. This is normal and does not damage the valve or hinder its function. The severity and
travel of this rapid motion depends on the amount of pressure differential across the valve gate. The greater
the differential, the more rapid the motion for a longer amount of the total valve stroke. The remainder of the
actuator motion should be smooth and uniform.
Upon removal of control pressure from actuators mounted on fail-closed valves, the motion should be smooth
throughout the entire stroke. Speed of this action depends on many factors such as how fast a differential
builds across the gate, is a locally mounted valve being used to exhaust the control pressure and the size of the
actuator and valve. As a general rule, the faster the control pressure is removed from the actuator the quicker
it will close.
The combination of compression spring assembly will provide approximately 8,000 pounds of force in the
closed position of the gate valve.
page 3
1.
2.
2M thru 15M
3.
API Classification
6A
3.
BB
4.
5.
Performance Rating
PR-2
6.
Temperature Classification
7.
8.
9.
10.
Actuator Volume
11.
Weight
12.
Dimensions
page 4
MODEL
in
3"
page 5
mm
in
29.50 749
D
mm
in
21.14 536
mm
in mm
13.25 336
2.25 57
in
mm
2.50 63
30.50 774
21.14 536
13.25 336
2.25 57
2.50 63
31.50 800
21.14 536
13.25 336
2.25 57
2.50 63
32.50 825
21.14 536
13.25 336
2.25 57
2.50 63
33.50 850
21.14 536
13.25 336
2.25 57
2.50 63
34.50 876
27.10 688
16.96 430
2.25 57
2.75 69
35.50 901
27.10 688
16.96 430
2.25 57
2.75 69
36.50 927
27.10 688
16.96 430
2.25 57
2.75 69
37.50 952
27.10 688
16.96 430
2.25 57
2.75 69
B
All Upper Housing
Threads are
8 UN-2A
MODEL
SWEPT VOLUME
in3
cm3
34.0
557
CLOSING TIMES
seconds
23
WEIGHT
lbs
kgs
432
196
40.0
587
34
432
196
46.0
675
56
440
199
54.0
793
67
465
211
69.0
1013
89
450
204
84.0
1233
1011
455
206
98.0
1439
1112
465
211
150.0 2459
910
881
400
186.0 3049
1112
898
408
218.0 3573
1314
898
408
253.0 4147
1415
907
412
ORDERING INFORMATION
The following information should be provided when requesting a quote or issuing a purchase order to
Array Products for an APHW Actuator.
Actuator
Model of Actuator:_______________________________________________________________________________
Size of Actuator: ________________________________________________________________________________
Actuator Control Pressure Availability: ______________________________________________________________
Special Requirements:
Testing _______________________________________________________________________________________
Coating_______________________________________________________________________________________
Non-Rising Top Shaft___________________________________________________________________________
Certification / Specification_______________________________________________________________________
Cable Size and Style______________________________________________________________________________
Accessories
Fusible Lock Open Cap: __________________________________________________________________________
Fusible Manual Override: _________________________________________________________________________
Hydraulic Override: ______________________________________________________________________________
Stem Protector (Clear) (Metal):_____________________________________________________________________
Electronic Switches Proximity: ____________________________________________________________________
page 6
VALVE
BORE SIZE
15,000 PSI
1 1316
2 116
2 916
APHW 045 x 040
APHW 045 x 040
1511 psi
2155 psi
4 116
.322 x wp + 545 psi
.322 x wp + 545 psi
APHW 045 x 050
APHW 045 x 050
2108 psi
3150 psi
5 18
.521 x wp + 545 psi
.521 x wp + 545 psi
3 18
3 116
3,000 PSI
5,000 PSI
6 38
7 116
Note: The designed values provided above only apply to actuators manufactured for Array gate valves and are provided for reference only. See Note on Next Page
page 8
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1. To select the proper actuator size and control pressure you must first determine the
gate valve bore size and the maximum working pressure of the valve.
2. Now determine the maximum flowing and shut in pressure for production.
3. Determine the available hydraulic control supply pressure at location.
4. Using the appropriate gate valve bore chart, find the y-axis location and draw a vertical line to the top of the chart.
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required actuator control pressure to open the gate valve.
Example: A valve pressure of 8,400 psi requires an actuator hydraulic control pressure of 3,250 psi to open gate valve (APHW
045 x 040). See control pressure equation on pages 7 & 8.
PARTS LIST
page 14
1
7
#
DESCRIPTION
Top Shaft
Piston (AK)
10
11
Retainer Ring
12
Cylinder
13
14
15
16
17
18
19
20
Stem Nut
21
22
23
24
25
26
Housing
27
28
Bonnet Ring
29
Relief Valve
30
31
Nameplate (NS)
32
33
Washer
34
Washer
8
11
12
9
10
29
4
2
13
14
Stem
36
Drift Shim
37
Packing Retainer
38
O-Ring (BK)
39
O-Ring (BK)
40
41
Bonnet
42
Vent Fitting
43
Nameplate (NS)
44
18
33
16
17
21
19
15
20
22
26
23
35
36
38
27
25
24
37
28
39
16
BONNET
35
17
40
41
34
18
42
Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves
manufactured by companies other than Array Products. In those cases the specific differences are usually
limited to the design of the bottom of the bonnet and operating stem.
page 15
page 16
PROCEDURE
1. Examine the (Packing Retainer #37). Verify that bore
threads are clean and in good condition and o-ring grooves
are clean and in good condition.
2. Thoroughly clean the (Packing Retainer #37), removing all
foreign debris from the threads and o-ring grooves.
3. Thoroughly lubricate the entire part with assembly lubricant
and then set aside.
4. Examine the (Bonnet #41). Verify that bore and threads are
clean and in good condition.
5. Thoroughly clean the Bonnet bore and O.D. threads and
lightly lubricate packing box with assembly lubricant.
6. Install the (Polypak Seal #40) in the bonnet packing box
with the packing o-ring energizer facing down. Push the
packing rings down to a positive stop.
7. Pick up the Packing Retainer and carefully thread the
retainer into the Bonnet with clockwise rotation to a positive
stop. Tighten retainer securely with a pipe wrench. Remove
any metal shavings or bits of residue from wrench operation.
8. Install a 1/2" (Body Grease Fitting #43) in the tapped hole in
the Bonnet flange and tighten fitting securely. Use pipe tape
or liquid (Teflon).
9. Examine the (Bonnet Stem #35). Verify that threads are
clean and in good condition, seal surface is clean and free of
nicks, dings, burrs and scratches.
10. Lightly lubricate the entire seal surface of the stem with
assembly lubricant.
11. Pick up the Bonnet and place it on its side.
12. Pick up the Stem and pass the Stem through the Bonnet
and packing set, from the flange side of the Bonnet until
the Stem backseat contacts its stop point. CAUTION: Be
careful not to nick I.D. sealing surface of packing by nose
of bonnet stem. Note: The design of the Stem/Gate
connection will vary depending on size, working pressure
and manufacturer.
page 17
page 18
PROCEDURE
1. Push the (Bonnet Stem #35) down out of the (Bonnet #41) until the
stem end for gate adaptation is exposed.
2. Thread the gate onto the exposed portion of the stem in a closing
direction. Position gate as required by valve manufacturers installation
procedure.
3. Rotate the gate slightly in either direction to align the slot in the stem
with the mating hole in the gate lift nut. Drive the pin (supplied by the
valve) through the gate pin hole in the stem slot.
4. Install new bonnet seal ring (supplied with the valve) in the valve body
and then carefully lower the gate into the valve body, between the seats
and allow the bonnet to pass over the valve body stud.
5. Install the valve body nuts on the studs and make up connection as
required by valve manufacturer.
6. The (Bonnet Stem #35) should slide easily upwards by pulling the gate
up to the fully closed position with your hands. The (Stem Nut #20) can
be threaded onto the stem for better leverage. Do not use any other
device or tool to lift the (Bonnet Stem #35) to the fully closed position
other than previously mentioned.
page 19
page 20
19. Using lifting eye installed in top shaft, lift cylinder and piston assembly into bore of cylinder (Cylinder Adapter Ring
#15). CAUTION: be careful when lowering assembly for proper alignment. The cylinder and piston assembly will
stop on cylinder adapter ring shoulder. Remove lifting eye from top shaft.
20. Insert the (Housing Shear Ring #14) into the groove in the (Cylinder Adapter Ring #15). CAUTION: Make sure ring
is seated and spring outward. (Must fit tight into groove).
21. Insert (Housing Lock Ring #13) into groove inside of housing shear ring. Note: if for any reason the lock ring does
not install easily or is cocked in the groove remove and reseat shear ring, then reinstall lock ring.
22. Install four (Washers #33) and (Bolts #18) into four tapped holes in top of (Cylinder Adapter Ring #15). Apply
neverseez lightly to threads. Using wrench torque firmly.
23. Install a solid 1/2 npt plug in one of the tapped holes located at the top of the (Cylinder #12). The solid plug should
be sealed with Teflon tape or Teflon liquid sealant. Plug to remain during testing.
24. Apply (Nameplate #31) using four (Drive Screws #32) See illustration (Not Shown).
25. Apply (Caution Tag #30) to O.D. of cylinder. Must be in close proximity to safety relief device. (Not Shown)
26. Actuator testing can now begin. Consult section of actuator testing.
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page 23
GATE
GATE
ADD SHIMS
REMOVE SHIMS
page 24
page 25
page 26
page 27
19. Install the (Inner Spring #24) and (Outer Spring #25) onto the (Bonnet Ring #28) springs are at free
length position.
20. Place the (Upper Spring Plate #21) onto top of spring set, align spacing.
21. Insert (Spring Guide Tube #22) into bore of (Upper Spring Plate #21). Mustshoulder properly.
22. Place (Lower Spring Plate #23). Down into bore of (Spring Guide Tube #22).
23. Thread (Spring Adjusting Nut #19) onto (Stem Nut #20) in a clockwise manner. Use a large adjustable wrench
to load the spring set. Continue rotation until (Stem Nut #20) stops on the (Spring Adjusting Nut #19) shoulder.
Note: The springs may rotate. This is normal and presents no cause for alarm.
24. Engage the two lifting eyes with the overhead lifting device. Lift the actuator over and down onto (Bonnet Ring #28).
The Actuator should stop correctly on the shoulder of the bonnet ring.
25. At the bottom of the Actuator install the (Housing Shear Ring - Outer #17). The ring must seat into the groove
and be tight.
26. Install the (Housing Lock Ring #16) into groove space. The ring cannot lock or wedge on the groove. If this
occurs remove both rings and clean housing groove and reinstall.
27. Install four (Hex Head Bolts #18) and (Washers #33).
28. Remove lifting eyes from (Cylinder #12). Reconnect all accessories to actuator. Connect securely all piping and
valves to pressure entry port on actuator cylinder.
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The burst assembly incorporates four (4) components. The body, cap, disc and disc seat. The following instructions
explain the correct method to replace the burst disc assembly.
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box/open end wrench, engage the hex wrench flats on the burst disc housing.
Using a second wrench (adjustable/open box) engage the hex flat on the burst disc cap. (Figure 1) Rotate the cap in
a counterclockwise direction until completely disengaged. (Figure 2) Remove disc seat and metallic particles of
exhausted disc. Clean inner bore and threads from burst disc housing. Install disc into bore. (Figure 3 & 4)
Caution: The convex surface of the disc must be facing outward at the installer. (Figure 5) Carefully inspect the
disc prior to installation. Make sure the contact surface of the body is clean for the disc to seal. Install the disc seat
on top of the disc center carefully. The disc seat can be installed from either side as it is symmetrical. (Figure 6)
Engage hex wrench flats on burst disc cap with an adjustable/open end wrench. Rotate the cap in a clockwise
direction. Tighten securely. (Figure 7)
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box open end wrench, engage the hex wrench flats on the burst disc housing.
Firmly, rotate the housing in a counterclockwise direction. Caution: Do not work over the housing during removal.
Remove housing from actuator. Clean all Teflon tape or liquid residue from internal and external threads before
replacement. Wrap Teflon tape in opposite direction to normal thread engagement around the threaded end of
the housing. Wrap securely. If Teflon liquid is used apply generously. Thread housing in actuator. Rotate in a
clockwise direction. Tighten securely. Check burst disc cap for tightness. The burst disc assembly is ready for
pressure service.
Figure 1
Figure 2
page 30
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
page 31
TESTING
page 32
1. The new assembled actuator will be tested per API 6A, latest edition. The following
section is applicable to latest edition 10.16.6.
a. Verify the following that all mechanical lock open devices are removed when proceeding with operational testing
and back seat testing.
b. Hydrostatic testing of actuator, bonnet and gate valve may employ a mechanical override only. NO LOCK CAPS ARE
TO BE USED ON HYDROSTATIC TESTING.
c. Remove the pressure relief device from the actuator. After testing is complete the safety relief device will be
assembled to the actuator. Use a gauge or solid plug as a replacement.
d. In house testing will use hydraulic/nitrogen for functional testing. If problems arise during testing with the actuator,
disassemble. Repair and re-assemble.
e. All testing must be performed by certified assemblers and testers.
PERIODIC MAINTENANCE
The following maintenance schedule is recommended to insure safe and reliable operation of the
Array Model APPM Actuator.
MAINTENANCE OPERATION
Monthly
2.
Monthly
Monthly
4.
Monthly
5.
Monthly
1.
3.
INTERVAL
TROUBLESHOOTING
TROUBLE
Control Pressure in
Actuator Will Not Build
page 33
PROBABLE CAUSE
REMEDY
Insufficient pressure in
control line
Bonnet stem is not fully extende Grasp stem in bonnet and pull to full
extension,properly back seating system
fully extended and seated
TROUBLESHOOTING
TROUBLE
page 34
PROBABLE CAUSE
REMEDY
ACTUATOR SPECIFICATIONS
Maximum Operating Pressure:
Test Pressure:
API Material Class:
API Temperature Rating:
API Performance Requirement:
Can be certified for Offshore SSV:
BONNET SPECIFICATIONS
Bonnets Available for Valve Brands:
Size Range Available:
Pressure Ranges Available:
API Material Classes Available:
PSL-1, 2 or 3, Annex F
PR-1 or 2
L through X
Yes
2008 Array Holdings, Inc. All specifications and materials are subject to change without notice.