OPERATION & MAINTENANCE MANUAL

MODEL APP
PISTON PNEUMATIC ACTUATOR
TABLE OF CONTENTS
page 2
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. Actuator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III. Actuator Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
IV. Actuator Size, Dimensions, Weight & Volme . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
V. Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VI. Control Pressure Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
VII. Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VIII. Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
IX. Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
X. Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
XI. Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
XII. Actuator Valve Sizing Chart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XIII. Actuator Assembly Drawing/Bonnet Bill of Material . . . . . . . . . . . . . . . . . . . . . . 14
XIV. Field Removal and Replacement of the Model APP Piston and Retainer Nut Seal . . . . . . 15
XV. Field Removal and Replacement of Piston Actuator Top Shaft PolyPak™ Seal . . . . . . . . 17
XVI. Main Actuator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
XVII. Diaphragm Actuator Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
XVIII. Array Bonnet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
XIX Array Bonnet to Gate Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
XX. Actuator to Bonnet & Gate Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
XXI. Setting the Gate Valve Drift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
XXII. Field Removal and Replacement of Bonnet Seal Packing . . . . . . . . . . . . . . . . . . . . 26
Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
XXIII. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
XXIV. Testing & Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
XXV. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
XXVI. Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INTRODUCTION page 3

The Model APP actuator is a piston type, pneumatically-powered gate valve actuator designed to operate a
“fail-closed” or “fail-open” safety valve. It is ideally suited for wellhead safety valve applications, flow lines,
header valves and gathering lines. It can also be used for casing relief valve and storage valve applications.

The Model APP actuator is lightweight, easy to maintain and engineered to ensure years of trouble-free service
in the harshest of environments and operating conditions on land or off-shore.

The Model APP actuator can be delivered as an actuated valve assembly ready to be placed in service or as an
actuated bonnet assembly ready to mount on another manufacturer’s valve.

ACTUATOR OPERATION
Array model APP Pneumatic Piston 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 pneumatic control pressure to the actuator inlet port. Pneumatic 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 spring. It will open fail-closed gate valves. Removal
of this pressure allows the bonnet stem forces to return the valve gate to it’s 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 on the valve.

When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft
will depend on whether the valve is fail-closed and how much pressure differential is present across the valve
gate. Fail-closed valves 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 gate valve. The greater the differential,
the more rapid the motion for a longer amount of total valve stroke. The remainder of the actuator motion
should be smooth and uniform.

Upon removal of control pressure from actuator 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 quick exhaust 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.
ACTUATOR TECHNICAL SPECIFICATION page 4

1. Applicable Gate Valve Bores 113/16" thru 71/16"

2. Applicable Gate Valve W.P. 2M thru 15M

3. API Classification 6A

4. Trim (API 6A Material Class) BB

5. Temperature Classification P -20° to 180°F (-29°C to -82° C)

6. Maximum Operating Pressure 170 psi / 12 Bars

7. Maximum Test Pressure 255 psi / 18 Bars

8. Pressure Relief Device Setting (Bronze) 170 psi @ 130° F (12 Bars @ 54° C)

9. Actuator Volume See chart on page 5

10. Weight See chart on page 5

11. Dimensions See chart on page 5

MODEL APP PISTON PNEUMATIC ACTUATOR
ACTUATOR SIZES, DIMENSIONS, WEIGHT & VOLUME page 5

A B C D E F G
in mm in mm in mm in mm in mm in mm
1300 X 020 23⁄4 – 8 3.75 95 19.25 488 6.93 176 13.99 355 13.64 346 2.34 59
1300 X 030 23⁄4 – 8 4.37 111 19.87 504 6.97 177 13.99 355 13.64 346 2.34 59
1300 X 040 23⁄4 – 8 5.04 128 23.52 597 8.15 207 13.99 355 16.61 422 5.29 134
1300 X 050 23⁄4 – 8 6.82 173 33.84 859 8.89 225 13.99 355 23.72 602 8.74 221
1300 X 060 23⁄4 – 8 7.82 198 34.84 885 8.89 225 13.99 355 23.72 602 8.74 221
1800 X 030 3"– 8 4.82 122 28.70 729 8.89 225 19.27 489 21.01 533 8.24 209
1800 X 040 3"– 8 5.82 147 29.70 754 8.89 225 19.27 489 21.01 533 8.24 209
1800 X 050 3"– 8 6.75 171 30.64 778 8.89 225 19.27 489 24.01 609 8.24 209
1800 X 060 3"– 8 7.98 202 34.60 878 8.89 225 19.27 489 24.01 609 8.24 209
1800 X 070 3"– 8 8.04 204 34.60 878 12.19 309 19.27 489 24.02 610 7.88 200
2000 X 030 3"– 8 4.37 111 33.22 843 12.18 309 21.53 546 25.57 649 7.03 178
2000 X 040 3"– 8 5.25 133 34.10 866 12.19 309 21.53 546 25.57 649 7.03 178
2000 X 050 3"– 8 6.37 161 37.22 945 12.18 309 21.53 546 25.57 649 7.03 178
2000 X 070 3"– 8 7.91 200 38.76 984 12.18 309 21.53 546 25.57 649 7.03 178

B A

C F

D
E

ACTUATOR SIZE SWEPT VOLUME WEIGHT

in3 cm3 lbs kgs
APP 1300 x 020 460 7539 258 117
APP 1300 x 030 526 8621 276 126
APP 1300 x 040 658 10,785 284 130
APP 1300 x 050 790 12,948 306 139
APP 1300 x 060 982 16,095 335 152
APP 1800 x 030 1210 19,832 525 239
APP 1800 x 040 1442 23,634 550 250
APP 1800 x 050 1637 26,830 579 263
APP 1800 x 060 1895 31,060 625 284
APP 1800 x 070 2002 33,140 640 291
APP 2000 x 030 1471 24,110 688 313
APP 2000 x 040 1784 29,240 718 327
APP 2000 X 050 2097 34,370 793 361
APP 2000 X 070 2723 44,630 839 513

Note: Swept volumes represent the maximum actuator stroke.

ORDERING INFORMATION
page 6
The following information should be provided when requesting a quote or issuing a purchase order to
Array Products for an APP Pneumatic Piston Actuator.

Actuator
Model of Actuator:_______________________________________________________________________________

Size of Actuator: ________________________________________________________________________________

Actuator Control Pressure Availability: ______________________________________________________________

Special Requirements:

• Testing _______________________________________________________________________________________

• Coating_______________________________________________________________________________________

• Certification / Specification_______________________________________________________________________

Bonnet / Gate Valve

Gate Valve Bore Size:_____________________________________________________________________________

Rated Working Pressure of Gate Valve:______________________________________________________________

Temperature Rating: _____________________________________________________________________________

Material Class: _________________________________________________________________________________

PSL Rating:_____________________________________________________________________________________

PR Rating:______________________________________________________________________________________

Interface Drawing Availability:______________________________________________________________________

Accessories
Fusible Lock Open Cap: __________________________________________________________________________

Fusible Manual Override: _________________________________________________________________________

Hydraulic Override: ______________________________________________________________________________

Stem Protector (Clear) (Metal):_____________________________________________________________________

Electronic Switches Proximity: ____________________________________________________________________

 MODEL APP PISTON PNEUMATIC ACTUATOR
CONTROL PRESSURE EQUATIONS page 7

VALVE WORKING PRESSURE

VALVE 3,000 PSI 5,000 PSI 10,000 PSI 15,000 PSI

BORE SIZE

APP 1300 x 030 APP 1300 x 030

134 psi 198 psi
113⁄16 .013 x wp + 3 psi .013 x wp + 3 psi
APP 1800 x 030 APP 1800 x 030
72 psi 107 psi
.007 x wp + 2 psi .007 x wp + 2 psi

APP 1300 x 030 APP 1300 x 030 APP 1300 x 030 APP 1800 x 030
39 psi 63 psi 143 psi 122 psi
21⁄16 .012 x wp + 3 psi .012 x wp + 3 psi .014 x wp + 3 psi .008 x wp + 2 psi
APP 1800 x 030
82 psi
.008 x wp + 2 psi

APP 1300 x 030 APP 1300 x 030 APP 1300 x 030 APP 1800 x 030
54 psi 88 psi 173 psi 137 psi
29⁄16 .017 x wp + 3 psi .017 x wp + 3 psi .017 x wp + 3 psi .009 x wp + 2 psi
APP 1800 x 030 APP 2000 x 030
92 psi 107 psi
.009 x wp + 2 psi .007 x wp + 2 psi

APP 1300 x 030 APP 1300 x 030 APP 1800 x 030 APP 2000 x 030
76 psi 124 psi 122 psi 153 psi
31⁄8 .024 x wp + 4 psi .024 x wp + 4 psi .012 x wp + 3 psi .010 x wp + 3 psi
31⁄16 APP 1800 x 040 APP 2000 x 030
63 psi 103 psi
.012 x wp + 3 psi .010 x wp + 2 psi

APP 1300 x 040 APP 1300 x 040 APP 2000 x 040

112 psi 184 psi 153 psi
.036 x wp + 4 psi .036 x wp + 4 psi .015 x wp + 3 psi
APP 1800 x 040
41⁄16 97 psi
.019 x wp + 2 psi
APP 2000 x 040
78 psi
.015 x wp + 2 psi

APP 1300 x 050 APP 1800 x 050

178 psi 152 psi
51⁄8 .058 x wp + 4 psi .030 x wp + 2 psi
APP 1800 x 050 APP 2000 x 050
93 psi 123 psi
.030 x wp + 2 psi .024 x wp + 3 psi

APP 1800 x 070

71⁄16 164 psi
.054 x wp + 2 psi
APP 2000 x 070
135 psi
.044 x wp + 3 psi

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)
CONTROL PRESSURE EQUATIONS
page 8

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.

• APP Actuator size, description and bore size at maximum working pressure.

• 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 APP use this equation.

ACTUATOR SELECTION PROCEDURE

Determine gate valve specifications such as size, maximum rated working pressure,
projected shut-in pressure and maximum flow line pressure.

DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY

Determine maximum flow line pressure in gate valve.

What is the available hydraulic pressure supply at site?

Multiply the maximum flow line pressure by the matrix equation and add the remaining number of psi for
the total hydraulic pressure to be used to open gate valve.
APP SIZING CHART
page 9

113/16 Nominal Gate Valve

170
160 p si
+3
150
x wp
140
013
130 p =.
3 0C
120
0 x0
110 30
P1

Required Actuator Control Pressure (psi)

110 AP i
p+ 2 ps
7xw
90
00

to Open Valve at Full Differential

80
0C p=.
x 03
1800
70
60 APP
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi

21/16 Nominal Gate Valve

170
160 i
150 3 ps
p+
140
4 xw
130 .01
120 C p=
030 2 ps
i
110 x +
Required Actuator Control Pressure (psi)

300
08 x wp
P1
110
Cp = .0
90 AP i 030
ps x
to Open Valve at Full Differential

80 3 2 000
wp+ APP
3x
70
60 .01
C p=
50 30
40 0 x0
30
30 P1
AP
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi
APP SIZING CHART
page 10

29/16 Nominal Gate Valve

170
160
p si
+3
150
140
x wp
130
.017 si
= + 2p
120
Cp x wp
110 3 0 .0 09

Required Actuator Control Pressure (psi)

x0 p=
00 0C si
+3p
100
13 0 x 03 wp
90
PP 180 = .0 07 x
APP

to Open Valve at Full Differential

A
80
03 0 Cp
70 20 00 x
APP
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi

31/8 – 31/16 Nominal Gate Valve

170
160
i
ps

150
4
+

psi
p

140
2
w

p+ si
x

130
xw 3p
24

2 +
.01 wp
.0

120 x
= 10
=

p .0
Cp

110 0C p=
Required Actuator Control Pressure (psi)

3 C
x0
0

030
03

100 0
180 x
000
x

90 P 2
00

AP APP
to Open Valve at Full Differential
13

80
P
AP

70
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi
APP SIZING CHART
page 11

41/16 Nominal Gate Valve

170
160 si

i
i

ps
p ps
150 +2 3
+4 w p p+
140
xw
wp

9x 5
130 01 .01
5x

=. p=
.03

120
Cp C
40
110 40 0
p=

Required Actuator Control Pressure (psi)

0 0 0x
0x 20
0C

100
0 P
18 AP
04

90
PP

to Open Valve at Full Differential

0x

80 A
30

70
P1

60
AP

50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi

51/8 Nominal Gate Valve

170
i
psi

ps
i

160
ps

3
+2
+4

150
+
p
wp

xw

140
wp

0x

24

130
58 x

.0
03

120
=
=.
= .0

Cp
Cp

110
Required Actuator Control Pressure (psi)
50
Cp

50

x0

100
x0

00
050

90
20

to Open Valve at Full Differential

00

80
18

P
0x

AP
P

70
130

AP

60
APP

50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi
APP SIZING CHART
page 12

71/16 Nominal Gate Valve

170
160 si
2p

si
3p
150
p+

140
p+
xw

130
xw
54

120
44
= .0

= .0

110

Required Actuator Control Pressure (psi)

Cp

100
Cp
70

90
70
x0

to Open Valve at Full Differential

x0

80
800
000

70
P1

60
P2
AP

50
AP

40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi
ACTUATOR VALVE SIZING CHART PROCEDURE
page 13

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.

31/8 – 31/16 Nominal Gate Valve

170
160
i
ps

150
4
+

psi
p

140
2
w

p+ si
x

130
xw 3p
24

2 +
.01 wp
.0

120 x
= 10
=

p .0
Cp

110 0C p=

Required Actuator Control Pressure (psi)

3 C
x0
0

030
03

100 0
180 x
000
x

90 P 2
00

AP APP

to Open Valve at Full Differential

13

80
P
AP

70
60
50
Y AXIS

40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Valve Working Pressure (WP) x 1000 psi

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 8,100 psi requires a piston actuator pneumatic control pressure of 99.2 psi to open gate valve
(APP 1800 x 030). See control pressure equation matrix on page 7.
 PARTS LIST
page 14

# DESCRIPTION
1 Top Shaft
2 Seal Retainer (AK)
3 Retainer Ring (AK)
4 Rod Wiper (AK) 1
5 Polypak™ Seal (AK)
6 Wear Bearing (AK) 4 2
7 Top Plate Assembly 5

8 Shear Ring
3 6
9 O-Ring (AK)
10 Retainer Nut 7

11 O-Ring (AK) 22
12 O-Ring (AK)
8
13 Wear Bearing (AK) 21
14 Piston Assembly
15 O-Ring (AK)
9
19
16 Spring Retainer Plate
10
17 Spring 15
18 Down Stop 11

19 Lock Ring 16
14
20 Bonnet Ring
21 Pressure Relief Device (AK) 17
12
22 Housing Bolts (AK)
23 Cylinder 13
24 Lower Plate Assembly 24
25 Actuator Assy ID Tag (NS) 18

26 Drive Screw (NS)

41
27 Attachment Bolt
28 Locking Screws (AK) 23 27
29 Cam Clamp
32
30 Washer (AK)
28
31 Caution Tag (NS, AK)
20 29
BONNET
32 Packing Retainer 30
33
33 O-Ring (Inner) (BK)
34 O-Ring (Outer) (BK)
37
35 Test Fitting
36 Polypak™ Seal (BK) 36 35
34
37 Bonnet Stem
38 Bonnet
39 Bonnet Assembly ID Tag (NS)
38
40 Drive Screw (NS)
41 Drift Shims

(NS) = Not Shown

(AK) = Actuator Repair Kit Items Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves

(BK) = Bonnet Repair Kit Items 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.
FIELD REMOVAL AND REPLACEMENT OF THE MODEL APP PISTON page 15
AND RETAINER NUT SEALS
1. Disconnect power source going into actuator side nipple (1/2–14 NPT) inlet. Caution: Be sure to disconnect
pneumatic quick exhaust. (The piston or diaphragm in the quick exhaust may not shift totally thereby trapping a
small amount of air pressure in top case). This could be injurious to personnel.

2. Do not disconnect the pressure relief device

3. If electric proximity switches are installed remove them from top of actuator. Do not injure or mishandle. Be aware
when removing bracket so as to correctly install properly later. Caution: All wire leads must be replaced carefully.

4. Remove all lock open devices such as caps, fusible caps and overrides (mechanical and fusible). Caution: If fusible
or mechanical 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 or mechanical cap and set aside.

5. The location of and access to the piston actuator will determine the disassembly procedure. In some locations the
piston actuator should be removed from the site and repaired in a different location.

6. To replace the piston o-ring seal when the actuator is installed on the wellhead follow instructions below.
Caution: Remove quick exhaust valve from the control line to actuator.

7. Make sure safety valve is in fully closed position with bonnet stem backseated. Check (Test Fitting #35) on bonnet
to insure stem is backseated and not leaking.

8. Thread the 3/4-10 UNC lifting eye into the threaded end of top shaft. Tighten securely.

9. Using a box end wrench remove 4 (Housing Bolts #22) and (Washers #30) from (Top Plate Assembly #7) surface.

 emove split (Lock Ring #19) from groove located at stop surface of (Top Plate Assembly #7), set aside.
10. R

 sing a small flat blade screwdriver remove (Shear Ring # 8) from recess groove in housing. Visual access may
11. U
be hindered by dirt, grime etc..remove before extracting shear ring.

 emove (Top Plate Assembly #7) from (Cylinder #23). The top plate can be removed by using the two lifting
12. R
lugs located on the top plate and the lifting eye ring threaded into the top shaft. The top plate can be removed
as a single part. You can use the (Top Shaft #1) and lifting eye ring to remove the (Piston Assembly #14) and
(Top Plate Assembly #7) together. Be prepared to handle the weight as both components are heavy.

13. If piston and top plate are removed as a single unit, place both on a flat surface. Lift top plate off of piston
and set aside.

14. Thoroughly clean piston top plate and piston. Check for wear marks on piston (Wear Bearing #13) and
(Cylinder #23) I.D. Remove any grime or particles that may be in cylinder I.D.

15. Push (Top Shaft #1) thru (Piston Assembly #14) sub assembly. Inspect O.D. sealing surface. Clean and set aside.

16. Remove (O-Ring #12) from O.D. seal groove of (Piston Assembly #14). Clean O.D. seal groove on
(Piston Assembly #14). Inspect seal groove for surface finish and dings or nicks. Clean and inspect bad o-ring
for abrasions, cuts and tears. Lubricate O-ring groove lightly, set aside.

17. Remove (Retainer Nut #10) from (Piston Assembly #14). Use a 14" pipe wrench and rotate in a counterclockwise
direction. Clean inspect and remove any shavings from pipe wrench and nut.
18. Install three o-rings on (Retainer Nut #10). Install (O-Ring #11) into face seal. Lightly grease. Install (O-Ring #15)
2 each, into bore. Slightly grease. Clean threads on piston. Lightly brush on “Neverseez™” to threads on piston. page 16

Thread (Retainer Nut #10) into bore of (Piston Assembly #14). Grease area on top of piston for face seal o-ring.
Tighten securely with pipe wrench. Remove any metal particles from piston made by pipe wrench jaws.

19. Insert (Top Shaft #1) thru (Retainer Nut #10) bore. Wipe of excess grease from top shaft.

20. With piston sub assembly on a flat surface, install (O-Ring #12). Lightly grease o-ring and piston O.D. groove.
After o-ring is installed grease o-ring and groove generously.

21. Lift the (Piston Assembly #14) by the (Top Shaft #1) and center over the opening of the (Cylinder #23). Push down
evenly. Caution: Do not force or hit piston with hammer to force piston into cylinder bore. Make sure piston is
positioned level in top of cylinder.

22. Lift (Top Plate Assembly#7) up and down onto cylinder and piston assembly. Caution: Be careful to center (Top
shaft #1) with the seal bore of (Top Plate Assembly #7). With both hands, lower the top plate onto the cylinder. At
approximately 2” distance from the top of the cylinder allow the top plate to slide down and engage the piston
assembly. The movement will force piston into cylinder bore concentrically. The weight of the top plate assembly
will push the top piston assembly into the bore smoothly. Once the top plate assembly has stopped on the cylinder
shoulder push down forcibly to insure proper seating of shoulder. Note: If top plate is tight fitting into top of
cylinder and has not seated use a dead blow hammer, plastic or brass to tap plate into position.

23. Install (Shear Ring #8) into cylinder groove. Be sure to seat ring properly. Install (Lock Ring #19) into groove
space. The ring must seat properly with not high spots. If the (Lock Ring #19) will not install properly, remove
shear ring and clean and inspect groove. Then re-install shear ring.

24. Install (Housing Bolts #22) and (Washers #30) into tapped holes in top plate. Tighten securely to 25 to 30 ft lbs.

25. Reinstall a lifting eye in the top shaft tapped hole. Pick up the pneumatic piston actuator assembly and remove the
spring. Set spring aside.

26. If this is a new actuator assembly, it must be adapted to a gate valve adapted for with the appropriate bonnet
assembly for testing as an SSV. Otherwise, it can be mounted to a test fixture with stroke capabilities for API 6A
testing as an actuator.

27. The completed piston actuator assembly must be thoroughly inspected. Apply (Caution Tag #31) to top plate next
to a 12-NPT Port.

28. Apply (Actuator Assembly ID Tag #25) to lower case. Use 2 each (Drive Screws #26).

29. Test according to API 6A latest edition. This testing excludes hydrostatic testing of the actuator.

30. After testing is complete thread (Pressure Relief Device #21) into (Top Plate Assembly #7).

31. Use Teflon tape or Teflon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate.

32. All assembly and testing must be performed by certified personnel.

33. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will be
serialized and documented by certified personnel.
MODEL APP REMOVAL AND REPLACEMENT OF PISTON ACTUATOR page 17
TOP SHAFT POLYPAK™ SEAL
1. Disconnect power source going into actuator side nipple (1/2-14 NPT) inlet. Caution: Be sure to disconnect
pneumatic quick exhaust. (The piston or diaphragm in the quick exhaust may not shift totally thereby trapping a
small amount of air pressure in top case). Removing actuator from bonnet assembly when air pressure is still in
actuator can be injurious to personnel.

2. Do not disconnect the pressure relief device.

3. If electric proximity switches are installed remove them from top of actuator. Do not injure or mishandle. Be aware
when removing bracket so as to correctly install properly later. Caution: All wire leads must be replaced carefully.

4. Remove all lock open devices such as fusible caps and overrides (mechanical and fusible) and set aside.
Caution: If a fusible or mechanical lock open cap is installed on top of the piston actuator, prior to any disassem-
bly pressure actuator to full open position to release upward thrust load on cap. This operation will prevent
injury to personnel. After pressurizing actuator unscrew fusible or mechanical cap and set aside.

5. Remove (Retainer Ring #3) from top of threaded boss and set aside.

6. Remove (Seal Retainer #2) from bore of threaded

boss. Inspect (Wiper Ring #4) installed internally into
(Seal Retainer #2). Clean both parts and set aside.

7. Remove top shaft (Polypak™ Seal #5) and replace.

Inspect old Polypak™ for wear marks.

8. Clean top machined seal bore in top threaded boss.

Inspect for burrs and dings in sealing bore.

9. Clean and inspect exposed portion of top shaft. Look

for dings, marks and any surface imperfection that
cause a pressure leak.

10. Install (Polypak™ Seal #5). Grease bore generously

prior to installation. Push down to stop on shoulder.
O-ring must be facing downward toward gate valve /
bonnet end.

11. Install (Seal Retainer #2) and (Wiper Ring #4).

12. Install (Retainer Ring #3) into groove. Clean and

inspect groove prior to re-assembly. Lock retainer
ring securely.

13. Re-install pressure control line and quick exhaust

valve into side mounted (1/2-14 NPT) nipple. Tighten
securely. Pressurize piston actuator and check for
leaks prior to installation of accessories.
APP MAIN ACTUATOR ASSEMBLY page 18

The following outlines the assembly of the Pneumatic Piston Actuator in first sub assemblies and then into a final
assembly. All item numbers refer to the Bill of Material items.

Caution: It is imperative that when assembling the Pneumatic Piston Actuator, the assembly be free of all
flying debris.

PROCEDURE
1. Inspect the (Lower Plate Assembly #24) bore for surface imperfections. Check I.D. and O.D. for cleanliness, dings,
burrs or scratches. Set aside on clean flat surface.

2. Place the housing on flat surface with the bore facing up. Thoroughly clean the entire housing and lightly lubricate
the bore with assembly lubricant.

3. Clean the (Top Shaft #1). Verify that the shaft is clean and free of scratches and dents. Grease lightly and set aside.

4. Inspect the (Retainer Nut #10). Clean the three o-ring grooves. Check the grooves for burrs, dings and sharp edges.

5. Install three o-rings into the (Retainer Nut #10). Be sure all grooves are clean prior to installation. Install (O-Ring
#15) 2 each, into I.D. grooves. Install (O-Ring #11) 1 each into the face groove. Grease all three o-rings generously
after assembly. Set Retainer Nut aside.

6. Examine the (Piston Assembly #14) for proper coating. Inspect for dings, Burrs and sharp edges. Look at the
surface finish on the o-ring groove. Thoroughly clean the piston; remove all foreign debris from the threads.
Lubricate entire part lightly.

7. Place the piston on a clean, flat surface. The o-ring groove should be facing upward. Install the (O-Ring #12) into
the piston groove. Lightly grease the (O-Ring #12) prior to installation. After installation of the o-ring, grease more
generously.

8. Install the (Wear Bearing #13) into the outer diameter groove of the (Piston Assembly #14). Be sure that the two
ends meet correctly and there is no overlap pressure. Grease installed wear bearing generously.

9. With (Piston Assembly #14) located on a flat clean surface, Install the (Retainer Nut #10) by rotating by hand in
a clockwise direction will stopping. Engage the outer diameter of the retainer nut with 14” pipe wrench in a
clockwise direction. Tighten securely.

10. Place the (Piston Assembly #14) on its side. Slide the (Top Shaft #1) through the bore of the (Retainer Nut #10).
Push till shoulder of top shaft stops on nose of retainer nut, life entire assembly up by top shaft and place on a
flat clean surface. Set aside.

11. Place the (Top Plate Assembly #7). Inspect the entire part. Check for sharp edges, scratches, dings and burrs.
Thoroughly clean the (Top Plate Assembly #7), remove all debris.

12. Inspect and clean the top Boss bore. Check for sharp edges and burrs on threads. Check entire part for coating
and surface finish. Check (1/2" NPT) threads (2 places) on top of plate. Check o-ring groove for cleanliness,
no burrs, dings or sharp edges. Lightly grease the o-ring groove.

13. Install (O-ring #9) into groove of (Top Plate Assembly #7) and lightly grease.

14. Install (Wear Bearing #13) into bore of (Top Plate Assembly #7), make sure ends do not overlap and stick up
preventing piston from sliding into cylinder.

15. Install (Polypak™ Seal #5) into (Top Plate Assembly #7) threaded Boss bore. Make sure o-ring energizer is facing
downward toward bonnet/valve end. Push Polypak™ to stop on shoulder.

16. Install (Wiper Ring #4) into I.D. bore of (Seal Retainer #2).
17. Install (Seal Retainer #2) into bore of top plate. Push down to contact (Polypak™ Seal #5).
page 19
18. Install (Retainer Ring #3) into groove at top of threaded boss. Use a blade screwdriver to seat retainer ring into groove.

19. Set assembled (Cylinder #23) aside.

20. Place the (Shear Ring #8) and (Lock Ring #19) together on a flat plane. Set the (Lower Plate Assembly #24) in the
middle of the two rings. These two rings will be installed after housing is in place.

21. Inspect the (Lower Plate Assembly #24) check the coating surface and finish and holes for sharp edges. Clean the
lower plate thoroughly.

22. When assembling the APP Pneumatic Actuator without a bonnet place the (Spring #17) into the cylinder of the valve
lower plate. Center spring.

23. Lift the (Cylinder #23) over and down onto shoulder of (Lower Plate Assembly #24). Allow cylinder to stop on
shoulder of lower plate. Rotate cylinder by hand to check for proper alignment.

24. Install (Shear Ring #8) into bottom side of (Lower Plate Assembly #24) Ring must snap into groove. The fit must be
snug.

25. Install (Lock Ring #19) into groove adjacent to (Shear Ring #8). Ring must seat properly with no stick up or high
spots. Install (Housing Bolts #22), 4 each and (Washers #30), 4 each. Tighten securely.

26. Grease (Cylinder #23) generously the entire length. Lift the (Piston Assembly #14) by the (Top Shaft #1) and center
over the opening of the (Cylinder # 23). Push down evenly. Caution: Do not force or hit piston with hammer to force
piston into cylinder bore.

27. Lift (Top Plate Assembly #7) up onto cylinder and piston assembly. Caution: Be careful to center (Top Shaft #1)
with the seal bore of (Top Plate Assembly #24). With both hands, lower the top plate onto the cylinder. At approxi-
mately 2" distance from the top of the cylinder allow the top plate to slide down and engage the piston assembly.
The movement will force piston into cylinder bore concentrically. The weight of the top plate assembly will push the
top piston assembly into the bore smoothly. Once the top plate assembly has stopped on the cylinder shoulder push
down forcibly to insure proper seating of shoulder.

28. Install (Shear Ring #8) into cylinder groove. Be sure to seat ring properly. Install (Lock Ring #19) into groove space.
The ring must seat properly with not high spots. If the (Lock Ring #19) will not install properly, remove shear ring
and clean and inspect groove. Then re-install shear ring.

29. Install (Housing Bolts #22) and (Washers #30) into tapped holes in top plate. Tighten securely to 25 to 30 ft lbs.

30. Reinstall a lifting eye in the top shaft tapped hole. Pick up the pneumatic piston actuator assembly and remove the
spring. Set spring aside.

31. If this is a new actuator assembly, it must be adapted to a gate valve adapted for with the appropriate bonnet
assembly for testing as an SSV. Otherwise, it can be mounted to a test fixture with stroke capabilities for API 6A
testing as an actuator.

32. The completed piston actuator assembly must be thoroughly inspected. Apply (Caution Tag #31) to top plate next to
a 1/2-NPT Port.

33. Apply (Actuator Assembly ID Tag #25) to lower case. Use 2 each (Drive Screws #40).

34. Test according to API 6A latest edition. This testing excludes hydrostatic testing of the actuator.

35. After testing is complete thread (Pressure Relief Device #21) into (Top Plate Assembly #7).

36. Use Teflon tape or Teflon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate.

37. All assembly and testing must be performed by certified personnel.

38. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will be
serialized and documented by certified personnel.
PISTON ACTUATOR EXPLODED VIEW
page 20
 page 21

ARRAY BONNET ASSEMBLY

The bonnet is part of the actuator that connects the actuator to the valve. The following outlines the assembly of the
Array Bonnet Assembly. All item numbers correspond to Bill of Material items.

CAUTION: It is imperative that when assembling the Bonnet, the assembly area be clean and free of all flying debris.

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. Install (O-Ring #33) and (O-Ring #34) to (Packing Retainer #32).

3. Thoroughly lubricate the entire part with assembly lubricant and

then set aside.

4. Examine the (Bonnet #38). Verify that bore and threads are clean
and in good condition.

5. Thoroughly clean the Bonnet bore and outer diameter threads and
lightly lubricate packing box with assembly lubricant.

6. Install the (Bonnet Packing #36), 3 pieces, 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 #32) and carefully thread the

retainer into the Bonnet with clockwise rotation to a positive stop.
Tighten retainer securely with a pipe wrench. Note: Remove any
metal shavings or bits of residue from wrench operation.

8. Install a (Test Fitting #35) in the tapped hole in the Bonnet flange
and tighten fitting securely. Use pipe tape or liquid (Teflon).

9. Examine the (Bonnet Stem #37). Verify that threads are clean and
in good condition, seal surface is clean and free of nicks, dings,
burrs or 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. Pass the Stem through the Bonnet and packing set, from the
flange side of the Bonnet until the Stem backseat contacts it’s
stop point. Caution: Be careful not to nick I.D. sealing surface
of packing by nose of bonnet stem.

 ote: the design of the Stem/Gate connection will vary depending

N
on size, working pressure and manufacturer.
 page 22

ARRAY BONNET TO GATE VALVE ASSEMBLY

The Array Products Bonnet Assembly when installed on an unbalanced valve is the interface between the Actuator and
the gate valve. The Bonnet will provide leak free sealing. Before adapting the actuator the bonnet stem should be
stroked freely by hand in both directions. When the valve is pressurized in the full closed position the stem will be urged
outward because of the valve pressure acting on the bonnet stem diameter.

The Array Products bonnet is used as an up and down stop for the valve. This design prevents damage to the valve
bonnet stem in the event of accidental over pressuring of the actuator.

The bonnet provides positive stroke reliability by use of spacers (provided with the actuator). Once proper stroke has
been set, a constant stroke distance will be maintained through the normal service life. All Array bonnet assemblies
are shipped ready for installation on the valve.

Warning: If you are installing a pre assembled Fail safe bonnet and Actuator assembly to
a gate valve some precautions need to be taken to prevent damage to the assembly. While
installing the gate to the bonnet stem the stem must not be back seated. Apply sufficient
control pressure to the actuator to unseat the fire seal. This will prevent damage to the
fire seal in the event the stem is rotated during installation of the gate. If the stem must
be rotated to align the gate to the gate valve, it can only be rotated in the clockwise
direction. If the stem is rotated in the counterclockwise direction it may unscrew from the
down-stop. This will affect the drift setting of the valve and could cause damage to the
actuator and the valve assembly. The stem will not rotate in the clockwise direction with
full actuator control pressure applied. You must only apply enough control pressure to
allow access to the gate to stem connection.

WARNING: During installation pay special attention to removal of any devices on the
valve such as stem balancing components, internal gate down stop devices and any
adjustments to gate travel.

PROCEDURE
1. Push the (Bonnet Stem #37) down out of the (Bonnet #38) until the stem end
for gate adaption is exposed.

2. Thread the gate onto the exposed portion of the stem in a closing direction.
Position gate as required by valve manufacturer’s 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.

6. The (Bonnet Stem #37) should slide easily upwards by pulling the gate up to the
fully closed position with your hands. The (Downstop #18) can be threaded onto
the stem for better leverage. Do not use any other device or tool to life the
(Bonnet Stem #37) to the fully closed position other than previously mentioned.
ACTUATOR TO BONNET & GATE VALVE ASSEMBLY page 23

1. The bonnet assembly is installed on a reverse acting gate valve. (See bonnet to gate valve assembly) and the drift
properly set with the correct amount of shims. (See setting the valve drift section)

2. With Bonnet and valve assembled in the vertical position, thread the (Bonnet Ring #20) onto end of (Bonnet #38).
Rotate by hand in a clockwise manner till tight. Lock the thread by installing a bolt into hole completely. Using a
dead blow hammer tap bolt head to tighten (Bonnet Ring #20) securely. Tap bolt so bonnet ring rotates in a
clockwise direction.

3. Install two (Locking Screws #28) and (Cam Clamps #29) into tapped
holes at base of (Bonnet #38). Tighten securely. Note: Make sure
flat on cam clamp is loading O.D. of bonnet neck.

4. Grease top of spring groove on (Bonnet Ring #20) lightly.

5. Install (Spring #17). Grease top of spring.

6. With (Bonnet Stem #37) fully extended, place (Spring Retainer Plate #16)
on top of spring. Place (Downstop #18) on end of (Bonnet Stem #37) and
rotate in a clockwise direction. Tighten securely. Note: Spring will rotate
while tightening stem nut. This is normal and
no cause for alarm.

7. Lift assembled actuator down onto assembled bonnet kit. Leave plugs out
of actuator side ports so air can exhaust. The actuator should drop down
and stop on bonnet ring shoulder. Align holes in lower housing to tapped
holes in bonnet ring. Torque 8 (Housing Bolts #22) to 60–75 ft. lbs.

8. Testing can now begin. Install a solid 1/2 NPT plug in one of the two nipples
located on the side of the top diaphragm housing.

9. Consult the particular API section of “Actuators”. The following section

applicable to testing is 10.16.

 fter completion of testing, install (Pressure Relief Device #21). Use

10. A
Teflon tape or Teflon liquid, tighten securely. Wipe off excess liquid if used.

 pply (Actuator Assembly ID Tag #25) using 2 (Drive Screws #26) to

11. A
(Lower Plate Assembly #24). Location should not interfere with exhaust
holes or bolt holes. Contour nameplates to fit outer diameter of housing.
Eliminate any sharp edges that may cause injury to personnel.
 page 24

SETTING THE GATE VALVE DRIFT

1. Setting the drift can only be accomplished after the bonnet assembly has been installed on the gate valve. All studs
and bolts have been torqued with all stem to gate connections completed.

2. With the gate valve in the vertical position, place four (Drift Shims #41) on top of the packing retainer.

3. Thread the (Downstop #18) onto the bonnet stem to a dead stop.

4. Using both hands, push down on the stem nut to bottom out on top of the shims.

5. Check the drift alignment by running the appropriate size drift tool through the bore. If the gate is not aligned with
the valve bore, pull up on the stem to the fully closed position and remove the down stop and add or subtract shims
as required to properly align the gate with the gate valve bore. (See Illustration)

6. The stroke length is now set permanent.

 page 25

GATE

GATE

ADD SHIMS REMOVE SHIMS

FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING page 26

1. Disconnect power source going to actuator pressure inlet.

2. Do not disconnect the pressure relief device

3. If a quick exhaust valve is used, disconnect from actuator and set aside. Caution: The piston or diaphragm in the
quick exhaust may not shift totally thereby trapping a small amount of air pressure in top case. This could be
injurious to personnel.

4. If electronic proximity switches are installed remove them from top of diaphragm case. Do not injure or mishandle.
Set aside. Be aware when removing switch bracket so as to correctly install properly later. Caution: All wire leads
must be replaced carefully.

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 or mechanical 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 or mechanical cap and
set aside.

6. Remove all (Attachment Bolts #27), 8 each, from base of Actuator (Lower Plate Assembly #24). Caution: Remove
bolts in a star method. If the removal torque becomes harder as you remove the bolts there could be pressure
trapped in the piston actuator. Remove pressure before continuing to remove bolting. Lift actuator off of spring
cartridge and bonnet and set aside.

7. Remove piston actuator from bonnet kit and set aside. If weight is a problem add a lifting eye (full thread
engagement) to top shaft and lift by mechanical means.

8. Using a spanner wrench remove (Downstop #18) by rotating in a counterclockwise direction.

9. Remove (Spring Retainer Plate #16), (Spring #17), and (Drift Shims #41), set aside.

 emove (Packing Retainer #32), rotate in a counterclockwise direction, using a pipe wrench. Caution: Be careful
10. R
not to nick the sealing surface O.D. of the (Bonnet Stem #37) with the removal of the (Packing Retainer #32).
Caution: 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 bonnet stem and set aside. Caution: Check for H2S ppm
well content. Be prepared to wear proper protection if well content is above safe levels.

11. Remove (Bonnet Packing #36), 3 rings. Use o-ring pick to remove rings out of bore.

 lean packing bore and grease generously. Install (Bonnet Packing #36) with o-ring energizer facing down toward
12. C
gate valve. Do not use pointed or sharp objects to push packing down into bore. Completely set all three pieces
of packing.

13. Re-install (Packing Retainer #32). Tighten firmly.

14. Install same number of (Drift Shims #41) onto packing retainer.

15. Install the (Spring #17) onto the (Bonnet Ring #20) at the free length position.

16. Thread the (Downstop #18) and (Spring Retainer Plate #16) onto end of (Bonnet Stem #37). Downstop must stop
on shoulder.

17. Lift actuator onto bonnet assembly. The actuator (Lower Plate Assembly #24) will stop on the shoulder of the
(Bonnet Ring #20).
18. Actuator should slide onto bonnet ring shoulder. Excess air inside housing will exhaust through pressure port.
(2) Leave open one of the pressure ports on top of Actuator housing. Air must escape through this port to be page 27
installed properly.

19. Align holes on (Lower Plate Assembly #24) with tapped holes in (Bonnet Ring #20). Install 8 (Attachment Bolts
#27) and torque to 60 to 75 ft. lbs.

20. Reconnect all accessories to actuator. Securely connect all piping and valves to pressure entry port of actuator
inlet nipple. Attach all electrical and fusible accessories to top of actuator if applicable.
SERVICING ARRAY MODEL APP ACTUATORS page 28

1. Prior to servicing the actuator assembly, it is recommended that this manual be read in its entirety. Should the
service technician have any questions or feel that a certain procedure cannot be performed safely, contact the
factory for assistance.

2. For safety precautions and due to the weight and/or size of some actuator assemblies and the presence of
pressurized fluids in the actuator and valve, personnel should be wearing the proper safety equipment such as
steel toe shoes, hard hats, safety goggles and lifting support belts.

3. When moving an actuator assembly or heavy parts, suitable lifting devices such as hoists should be used. It is
recommended that the weights of the equipment being serviced be obtained from the appropriate gate valve
manufacturer’s technical bulletins to confirm that any lifting equipment to be used is adequate. Caution: When
using lifting eyes make sure they are forged single piece design. Engage thread completely before lifting.

4. DO NOT attempt to remove any items from the actuator assembly when it is pressurized. BLEED OFF ALL control
pressure and disconnect the supply lines before performing any service functions. Failure to do so could result
in equipment damage or personal injury.

5. The work are should be clean and free of contaminents such as dirt, sand and metal shavings etc.

6. All grease or lubricants must be free of any contaminents. Any utensils such as brushes or applicators must also
be free of any foreign particles.

7. All tools used should be clean, in good working order and be the proper tool for the operation to be performed.

8. Keep all elastomers and/or replacement parts in the original storage or shipping packaging until installed.

9. Cleaning must be finished prior to installation or inspection of any new or used component. A suitable fluid should
be used that is compatible with the part being cleaned. Most naptha based solvents are good for heavy de-greasing
of metallic parts. A solution of warm soap and water is recommended for all non-metallic pieces or simply wipe
with a clean cloth. The use of commercially available aerosol dispensed brake cleaners may be used on metal
parts only. Caution: If part is coated, test the vapor build up if using indoors.

10. All new or used parts must be examined after cleaning burrs, dings and nicks prior to using them.

11. Lightly lubricate all seals and sealing surfaced with a suitable grease prior to installing them.

12. When handling any parts that have sealing surfaces, care should be taken not to mar those surfaces.

13. C
 aution: failure to follow the procedures given in this manual may result in equipment damage, operating
problems and/or personal injury.
TESTING page 29

1. The new assembled actuator will be tested per API 6A, latest edition. Section 10.16 is applicable.

a. Verify 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 APD Actuator.

MAINTENANCE OPERATION INTERVAL

1. Cycle actuator under normal operating conditions. Monthly

2. Inspect pressure relief device Monthly

Check for leakage around threads.

3. Inspect Top Shaft Monthly

4. Check top shaft packing retainer and retainer ring Monthly

in top of cylinder

5. Replace All Seals Every five (5) years or

when leakage occurs
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
Actuator will not stroke
on a Valve Whether or not
Valve is Pressurized
Actuator will not attach to
Bonnet Assembly
(Bonnet Ring)
Actuator will not stroke to
full closed or
‘Fail Safe Close’ Position
Insufficient pressure in
control line
Valve and/or seats improperly
installed
Gate/Seat Galled
Debris in shaft or housing
Bonnet stem is not fully
extended.
Bad or wrong thread on bonnet Check threads on bonnet and pull
stem and down-stop on bonnet/
ring assembly
Spring cartridge too long
because of bonnet engagement
to down stop
Downstop not fully engaged to
bonnet stem
Gate and seats are improperly
installed causing excessive
friction
Excessive seal friction due to
loss of lubrication in bonnet/valve
Improper gate to stem
engagement
page 30
Verify pressure availability from source.
Consult control pressure information
from the sizing chart or matrix.
Remove actuator as instructed per this
manual. Remove bonnet as per bonnet
manufacturer’s operating instructions.
Repair and/or replace valve components
as per valve manufacturers repair manual.
Remove bonnet kit. Inspect gate and
seats and replace if necessary.
Re-inspect housing and spring
Grasp stem in bonnet and pull to full
extension properly back-seating system.
to full extension properly back-seating
system.
Check thread engagement on bonnet
stem and downstop for burrs, nicks,
dings and debris. Check size and thread
pattern for proper engagement.
Remove actuator and tighten downstop
to bonnet stem.
Remove actuator as instructed per this
manual. Manually push and/or pull
bonnet stem to determine severity of
binding. If severe, remove bonnet, gate
and seats, clean and inspect gate and
seats for wear and abrasion. Replace
if necessary.
Lubricate in accordance with manufac-
turer’s maintenance manual
Remove actuator as instructed per this
manual. Remove bonnet as per bonnet
manufacturer’s instructions and/or
drawings, re-assemble. This problem
only applies to certain valves.
TROUBLESHOOTING
TROUBLE PROBABLE CAUSE REMEDY
Actuator housing stops
prior to aligning with
bonnet ring
Piston Pneumatic
Actuator will not stroke to
open position. Actuator
is in fully closed position
Bonnet ring threaded down to
positive stop
Actuator control supply
too low (psi)
Shut in tubing head pressure
too high (psi)
Piston o-ring leaking
Piston retainer nut
o-rings leaking
Top Shaft Polypak™
seal leaking
Relief valve or burst disc bad
Bad quick exhaust valve
(piston not shifted)
Upstream Seat sealing on gate
(double blocked)
Gate galled against seat
Packing seized
page 31
Check for thread engagement between
downstop and bonnet stem
Check regulator and control
pressure gauge
Gauge on top cap illustrates shut in
pressure/flowing. Change actuator
control Actuator will not stroke after
psi increase.Contact factory or
double actuators.
Air will flow through four holes at base
of lower housing. Use (snoop) or a
soapy substance.
Remedy same as above
 Spray (snoop) on top seal around top
shaft. (Will bubble up) Replace seal.
Air will exhaust, hold hand over to check.
(CAUTION!)
Remove quick exhaust check piston or
diaphragm for movement
Valve could be double blocked. Bleed
down body pressure if applicable
Remove actuator downstop, spring
retainer and spring, negotiate bonnet
stem by hand
Remedy same as above
MODEL APP PISTON PNEUMATIC ACTUATOR

page 32

ACTUATOR SPECIFICATIONS
Maximum Operating Pressure: 170 psi / (12 Bars)
Test Pressure: 255 psi / (18 Bars)
API Material Class: BB
API Temperature Rating: P -20º F to 180º F (-29º C to -82º C)

BONNET SPECIFICATIONS
Bonnets Available for Valve Brands: Any Manufacturer (with Current Interface Drawing)
Size Range Available: API 6A 113/16” through 71/16”
Pressure Ranges Available: See Control Pressure Chart
API Material Classes Available: AA,BB,CC (non-NACE)
DD-0,5 / DD-1,5 / DD-NL
EE-0,5 / EE-1,5 / EE-NL
FF-0,5 / FF-1,5 / FF-NL
HH-NL
API Product Specification Levels Available: PSL-1, 2 or 3
API Temperature Ratings Available: L through X

LIMITED PRODUCT WARRANTY

The following warranty is exclusive and in lieu of all other ARRAY’s obligation under this Warranty is limited to use
warranties. Whether express, implied or statutory, including, reasonable efforts to repair, replace or, at it’s option, refunding
but not by way of limitation, any warranty of merchantability the purchase price. The cost of labor for installing a repair or
or fitness for any particular purpose. replacement product shall be borne by Purchaser. Replacement
parts provided under the terms of this Warranty are warranted for
Array Products warrants to each original buyer of products
the remainder of the warranty period of the products upon which
manufactured by Array that such products are free from defects
they are installed to the same extent as if such parts were original
in material and workmanship under normal use and service for a
components thereof. Warranty services provided there under do
period of one (1) year from the date of shipment provided that no
not assume any liability for damages caused by any delays
warranty is made with respect to: Any product which has been
involving warranty service. For complete specification information,
repaired or altered in such a way in ARRAY’s judgment, as to
prices and name, address and telephone number of the ARRAY
affect the product adversely; Any product which has, in ARRAY’s
representative nearest you, call or write to us at the address below.
judgment, been subject to negligence, accident or improper
storage; Any product which has not been operated or maintained
in accordance with normal practice and in conformity with
recommendations and public specification of Array.

ARRAY HOLDINGS, INC., D.B.A.

ARRAY PRODUCTS
15900 Morales Road, Houston, Texas 77032
Phone: 281.977.8500 • www.array.com

©2010 Array Holdings, Inc. All specifications and materials are subject to change without notice.