Sempell Pneumatic Drive Type A 160 IOM Owner's manual

Brand: Sempell

Model: Pneumatic Drive Type A 160 IOM

Type: Owner's manual

SEMPELL

Pneumatic Actuator Type A 160

Operating Instructions

SEMSH-0067-EN-1310

Design according to TO.270.07

Observe design data on the nameplate!

Foruseofacontrol device STE 4 or STE 5 observe

corresponding operating instruction!

www.valves.emerson.com

Contents

1 Danger and Warning Indications 2

2 Description 2

3 Operation 2

3.1 Storage Rules 3

3.2 Compressed-Air Connection 3

3.3 Pressure Test 3

3.4 Commissioning 3

4 Inspection and Maintenance Works 4

5 Disassembly 4

5.1 Danger and Warning Indications 4

5.2 Tools 4

5.3 Utilities 4

5.4 Removing the Pneumatic Actuator A160 4

5.5 Dismantling the Pneumatic Actuator A160 4

5.6 Removal of the Valve Bonnet by Means of the Pneumatic Actuator A160 5

6 Assembly 5

6.1 Assembly of the Valve Bonnet 5

6.2 Assembly of Pneumatic Actuator A160 5

6.3 Mounting the Pneumatic Actuator A160 5

6.4 Adjusting the Pneumatic Actuator A160 6

7 Drawings 7

7.1 Assembly drawing A160 7

7.2 Safety valve with Pneumatic Actuator A160 8

8 Determination of the Characteristics 9

8.1 Calculations 9

8.2 Characteristics Safety Valves VSE / VSR 10

8.3 Characteristic Safety Valves Series S DIN 10

Emerson reserves the right to change the content without

notice MA.270.07.0905 E

Attention!

This operating instruction is only valid in

connection with the operating instruction

of the pertaining safety valve.

Pneumatic Actuator Type A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 2

1 Danger and Warning Indications

Danger for Persons and Materials

• Use pneumatic actuator only for the intended purpose.

• Additional mountings and modifications to pneumatic actuator and assemblies are only allowed

with our approval. The same applies for foreign accessories or spare parts.

• Observe installation instructions.

• Adhere to the rules for prevention of accidents and safety instructions related to plant.

Application Limits

It is only allowed to use the actuators

according to the details of this operating

instruction and according to the

parameters and application cases agreed

in the delivery contract (see nameplate).

Avoidance of Danger

Working at valves only by skilled personnel and with special work permit.

For disassembling the system wait for official permission. The system has to be pressureless.

After each action control ready-to-operation state of actuator and safety valve. Control all sealing

points.

Exclusion of Liability

Sempell GmbH does not accept liability when a/m regulations, instructions and warning indications

are not observed and adhered to.

2 Description

Application

The pneumatic actuator A160 is designed for the supplementary loading of safety valves and is

triggered by control device STE4 or STE5.

The working pressure difference of the safety valve can be reduced by supplementary loading.

Thereby, the margin between set pressure of safety valve and working pressure of the system is

smaller than 10% of the set pressure.

The supplementary loading (normally 20 – 30 % of the spring force of the spring loaded safety

valve) results in higher tightness at the valve seat. Opening and closing pressure differences can be

reduced. The safety valve also can be opened below the set pressure by means of the pneumatic

actuator.

To specify the supplementary loading see chapter 8.

Functioning

In normal operating state, compressed air in the space above the piston produces the

supplementary loading. The piston of the pneumatic actuator is connected with the spindle of the

safety valve.

The set pressure is adjusted by the pressure switches of the control device (STE4 or STE5). Exceeds

the system pressure the adjusted set pressure the supplementary loading is released. At the same

time lifting air is applied to the space below the piston. The safety valve opens.

If the system pressure drops below the adjusted closing pressure, the lifting air will be released and

the supplementary loading applied again. The safety valve closes.

3 Operation

3.1 Storage Rules

To preclude damages during loading and unloading move the valves cautiously. Levers and

other parts are unsuitable as lifting points. The transport shall preferable take place by crane or

transport pallet.

At delivery the outsides of all steel parts of the safety valve are supplied with a coat of paint

except the welding edges and gasket surface(s).

All connections are closed by suitable caps.

In this state the safety valve with pneumatic actuator can be stored in closed, dust-free and dry

rooms lying on a pallet without difficulties. Time of storage about six months.

Storage of more than six months asks for disassembly and visual check of the inner parts of the

safety valves. A weather-protected outside storage is not allowed.

Attention!

In each case observe the danger and warning indications of the operating instruction of the

pertaining safety valve.

Attention!

Observe and adhere to the precautions marked in the sections of this operating instruction.

Pneumatic Actuator Type A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 3

• For spare parts out of elastomers

(O-rings, scraper rings, rod and piston gaskets) additionally apply:

Temperature: The temperature of the storage shall be between 0°C and 25°C since otherwise

a hardening of the material and so a shortening of durability will follow. Shield heating

elements and lines in heated storeroom so that no direct heat irradiation arises. The distance

between the heat source and the stored goods has to be 1 m at least.

Moisture: To prevent the formation of condensate, avoid moist storerooms. A relative humidity

of below 65 % is at best.

Lighting: The elastomers are to be protected from direct sun light and from strong artificial

light with a high ultraviolet content. Therefore cover the windows of the storerooms with a red

or orange (in no case blue) paint.

Ozone: Protect elastomers against ozone (formation of cracks and embrittlement). The

storeroom may not contain ozone generating systems (fluorescing sources of light, mercury

vapor lamps, electric motors, etc.).

Oxygen: Protect elastomers from draught by storage containers. Oxygen causes cracking and

embrittlement.

If these requirements are guaranteed for elastomers the storage time is about 5 years.

• For spare parts out of steel:

Store the parts in closed, dust-free and dry rooms so that damages do not occur.

3.2 Compressed-Air Connection

The connections of the lifting and loading air lines are lateral to the pneumatic actuator. The

pertaining compressed-air hoses (attached to delivery) enable the tension-free connection to

the pneumatic actuator.

The compressed-air hoses for pneumatic actuator have tube fittings including ferrule with

which pipe OD Ø 22 x 2 can be fastened.

IMPORTANT

• Clean the lifting and loading air lines by blowing out with compressed air before connection.

• Take care that the controlled air lines are correct assigned:

- Loading air line at the upper connection of the pneumatic actuator

- Lifting air line at the bottom connection of the pneumatic actuator

3.4 Commissioning

• Check functional readiness of actuator.

• Prove duly interaction of safety valve and control device STE4 or STE5. Check according to

operating instruction of the pertaining control device.

3.3 Pressure Test

Either flange off safety valve and close supply line with a blind flange or mechanically block the

valve. In case of welded-in safety valves a pressure test plug can be used.

Screw on cap (160.14) upside down to the piston rod (160.06) and sturdily tighten with

hexagonal screw (160.16) to the cylinder cover (160.02) so that the disc is blocked in closed

position.

Attention!

The lifting of the safety valve must be prevented.

Attention!

For blocked safety valve the test pressure can be up to 1.5x the set pressure without

consulting Sempell.

Attention!

In case of removed cap (160.14) take care that no dirt or parts fall into the cylinder.

Restore and control ready-to-operation state after the pressure test.

Pneumatic Actuator Type A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 4

5 Disassembly

5.1 Danger and Warning Indications

Attention!

Take work order and wait for official permission

Control if the pneumatic actuator is pressureless.

Before disassembling switch off power supply, loosen plug or disconnect cable.

5.2 Tools

• fixed spanner 10 - 36 mm

• socket wrench 6, 8 mm

• screwdriver 8 mm

• retaining ring pliers for outer rings

• flatnose pliers

• side cutting pliers

• hammer

• punch Ø 2,5; 3; 4 mm

• seal wire

• lead seal

• lead-sealing pliers

• marking gage

5.3 Utilities

• Degreasant: Kaltron 113MDS/113MDK/113MDI35. Frigen 113TR-T.

• Freon PCA/TF/T-P35/TA. Isopropyl alcohol with acetone, mixture 1:1, white spirit.

• Lubricant for assembly (MoS

): Molykote-Spray, Dow Corning, Munich.

• Lubricant for assembly (Colloidal-Graphite) for parts in contact with the medium:

DAG156 Acheson, Dornstadt. Neolube 1, 2, Lubricant Consult, Maintal.

• Only to facilitate assembling:

Lubricating grease for bearings, spindle threads, screws and the like:

Molykote-BR2plus (≤ 80 °C); BG20 (> 80 °C), Dow Corning, Munich;

Barrierta L55/2 (> 120 °C), Klüber, Munich, Mobilgrease Spec., Mobil Oil

• O-ring grease: DOW Corning, Munich

5.4 Removing the Pneumatic Actuator A160

Measure and record the position of the coupling (71). Loosen allen bolts (72) and turn the

coupling (71) so far from the spindle until the piston (160.05) in the cylinder rests. Remove lead

seal. Bend up locking plates (68) and loosen hexagonal screws (67). Carefully lift pneumatic

cylinder a little (maximum piston stroke) and turn off coupling (71) completely from the spindle.

Horizontally remove coupling (71) and lift off pneumatic cylinder.

5.5 Dismantling the Pneumatic Actuator A160

Disassemble pneumatic actuator only if necessary.

Unscrew cap (160.14). Loosen screw bolts (160.11) and lift off upper cylinder cover (160.02).

Straighten locking plate (160.08) and loosen hexagonal nut (160.07). Remove piston (160.05).

In doing so, strongly hold cylinder (160.03) and lift off with the piston (160.05) together. If

required, remove cylinder (160.03) from the piston (160.05). For re-assembly use device.

Straighten locking plates (70) and loosen hexagonal screws (69). Remove cooling spacer (66).

Remark:

At pneumatic actuator A160.1 (cylinder diameter 125 mm) piston and piston rod are of one

piece.

4 Inspection and Maintenance Works

Inspection intervals depending on frequency of response and operating conditions, e. g. annually,

under severe conditions twice a year. Keep record on performed works.

At commissioning and at each inspection

• After the first pressure charge and each disassembly:

• Check each sealing point on tightness. Replace if leaky.

At disassembled pneumatic actuator

• Treat sliding guides, fittings, gaskets and threads with an assembling lubricant.

Attention!

When using Barrierta L55/2 carefully

clean components with white spirit

180/200 or Klüberalfa XZ3-1 before

assembling as otherwise loss of lubricity

is possible. Never mix Barrierta L55/2

with other lubricants.

160.14

160.16

Pneumatic Actuator Type A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 5

For the inspection and grinding of the valve seat, it is not necessary to completely disassemble

the safety valve. For this purpose, the complete valve bonnet with locked spring can be

removed.

Loosen hexagonal nuts at the screwing (160.21) and remove pneumatic hoses. Unscrew ring

screw (160.22) and hexagonal screws (160.16).

Remove cap (160.14), unscrew the eye bolt and place the screw the cap onto the piston rod

(160.06). Place the hexagonal screws (160.16) into the threaded holes of the cap (160.14) so

that the cap (160.14) is supported by the cylinder cover (160.02) of the actuator. Thus the spring

of the safety valve is locked. The hexagonal screws (160.16) shall be tightened securely by hand

only.

Attention!

Further disassembly of the removed complete valve bonnet is not allowed.

Attention!

The pressure spaces of the pneumatic piston must be pressure-released. Please check:

Pressure indicator at the manometer “Loading” and “Lifting” in the control unit shows 0 bar.

Attention!

At safety valves (VSE/VSR series V, SOH) and at higher set pressures the valve spring must be

blocked by means of the spring lock nut (98).

5.6 Removal of the Valve Bonnet by Means of the Pneumatic Actuator A160

Screw down spring lock nut (98) until a clearance of 0.5 – 1 mm is left between pressure screw

of the safety valve and spring lock nut (98). Loosen bonnet nuts, remove valve insert.

For further disassembly see corresponding operating instruction of the safety valve.

Clearance 0.5 - 1 mm

6 Assembly

6.1 Assembly of the Valve Bonnet

• Insert complete valve bonnet and tighten with bonnet nuts.

• If now - due to rework or replacement of the safety valve disc - the hexagonal screws

(160.16) are too tight or too loose, detach lock nut and adjust adjusting screw in such

manner that the hexagonal screws (160.16) sturdily rests again. Thus the same set pressure

is obtained as before. Secure adjusting screw with lock nut (see operating instruction of the

safety valve).

• Loosen hexagonal screws (160.16) and turn cap (160.14) from the piston rod (160.06). Put

cap (160.14) into the correct position on the cylinder cover (160.02) again and tighten with

hexagonal screws (160.16). Assemble ring screw (160.22) and O-ring (160.23).

6.2 Assembly of Pneumatic Actuator A160

• Slide cylinder (160.03) over the ring (160.10) into the piston (160.05), if possible with the

device. Insert piston rod (160.06) in the piston (160.05), tighten with hexagonal nut (160.07)

and secure it by bending the locking plate (160.08).

• Move cylinder cover (160.01, 160.02) with O-rings (160.04), rod guide rings (160.13, 160.20)

and Turcon scraper ring (160.19) on the piston rod (160.06) and tighten with screw bolts

(160.11) and hexagonal nuts (160.12).

• Mount cap (160.14) and O-ring (160.15). Fasten cooling spacer (66) with hexagonal screws

(69) and secure it by bending the locking plates (70). Hang in coupling (71).

• The Turcon scraper ring (160.19) in the lower cylinder cover (160.01) is fixed with a supporting

disc (160.17) and a retaining ring (160.18).

6.3 Mounting the Pneumatic Actuator A160

• Put pneumatic cylinder with coupling (71) carefully on the spindle and screw coupling (71)

on the spindle. In doing so, continue lowering the pneumatic cylinder. Fasten cooling spacer

(66) with hexagonal screws (67) and secure it by bending the locking plates (68).

• Move coupling (71) into the registered position and clamp with Allen bolts (72).

Pneumatic Actuator A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 6

6.4 Adjusting the Pneumatic Actuator A16

Attention!

In any case correctly adjust pneumatic actuator A160. An incorrect adjusted actuator may

impair the functioning of the safety valve.

The actuator must be pressureless.

Procedure

1. Make sure that the pneumatic actuator is pressureless.

2. Remove cap (160.14).

3. Loosen Allan bolts (72).

4. Move piston (160.05) into uppermost position up to the stop of the cylinder cover (160.02)

(by turning coupling (71)).

5. Measure dimension A.

6. Determine dimension B

[B = A - (valve lift - 1)]

7. Pull piston (160.05) downwards by means of coupling (71) until dimension B is reached.

8. Restore mechanical joint between coupling and valve spindly by tightening the allan

bolts(72).

Valve lift minus 1 mm

Spindle position upper piston stop

Adjustment of coupling

valve lift minus 1 mm

Valve spindle lowest position

(safety valve closed)

Ca. 2 mm

At type 160.14 ca. 4 mm

Important

During the adjustment the piston rod must rest upon the coupling!

160.22

160.23

160.25

160.21

160.13

160.19

160.17

160.18

160.16

160.14

160.20

160.1

160.0

160.04

160.03

160.05

160.10

160.11

160.04

160.01

160.1

160.07

160.08

160.09

160.06

160.26

Pneumatic Actuator A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 7

Spindle position upper

piston stop

Adjustment of coupling

valve lift minus 1 mm

7 Drawings

7.1 Assembly drawing A160

Pneumatic Actuator Type A 160

Operating Instructions

Emerson reserves the right to change the contents without notice page 8

7.2 Safety valve with pneumatic actuator A160

Pneumatic Actuator Type A 160

Operating Instructions

Emerson reserves the right to change the contents without notice page 9

8 Determination of the Characteristics

By means of the recommended pneumatic actuator all safety valves (see chapter 8.1 and 8.2)

obtain a supplementary loading of at least 30 %. The safety valves can be opened at a system

pressure of 85 % of the set pressure p with the pneumatic actuators. This applies for a control air

pressure of 6 bar.

8.1 Calculations

Supplementary loading

Supplementary loading is the additional sealing force (closing force) either percentage from the

adjusted spring force or referring to the set pressure according to the formula:

Example

Safety valve VSE orifice letter F (see section 8.1)

set pressure p = 130 bar

control air pressure pk = 5 bar

From table:

pneumatic actuator type A160.1.22

constant K1 = 15.1

K2 = 13.9

Z [%] =

K1 x pk

x 100%

Terms:

supplementary loading = Z, constant 1 = K1,

control air pressure [bar] = pk, set pressure [bar] = p

Required system pressure for compulsory opening of the safety valve below the set

pressure

The minimum pressure p (syst. A) at which the set pressure of the valve can be checked, is

calculated as follows:

p (sys.A) = p – K2 x pk

The minimum pressure p (syst. H), at which the valve can be compulsorily opened completely

up to the lift stop, approximately results from:

p (syst.H) = p –

K2 x pk

Terms:

constant 2 = K2, control air pressure [bar] = pk, set pressure [bar] = p

Z =

15.1 x 5

x 100% = 58.1%

130

p (sys. A) = 130 – 13.9 x 5 = 60.5 bar

p (syst. H) = 130 –

13.9 x 5

= 95.3 bar

A 200.0 A160.1.14.BO

34.90 32.20 40.0

500.0 A160.1.14.BO

65.90 60.70 –

B 200.0 A160.1.14.BO

34.90 32.20 40.0

450.0 A160.1.22.BO

34.90 32.20 –

C 200.0 A160.1.14 34.90 32.20 40.0

450.0 A160.1.22 34.90 32.20 –

D 90.0 A160.1.14 19.60 18.00 26.0

315.0 A160.1.22 19.60 18.00 –

E 90.0 A160.1.14 19.60 18.00 26.0

315.0 A160.1.22 19.60 18.00 –

F 80.0 A160.1.14 15.10 13.90 20.0

280.0 A160.1.22 15.10 13.90 –

G 63.0 A160.1.14 11.00 10.20 16.0

224.0 A160.1.22 11.00 10.20 –

H 56.0 A160.1.14 8.30 7.60 11.0

167.0 A160.1.22 8.30 7.60 –

200.0 A160.2.22 21.20 20.60 –

J 133.0 A160.1.22 6.30 5.80 10.0

180.0 A160.2.22 16.20 15.70 –

K 100.0 A160.1.22 4.70 4.40 8.0

160.0 A160.2.22 12.10 11.70 –

L 67.0 A160.1.22 3.50 3.30 6.0

140.0 A160.2.22 9.10 8.80 –

M 50.0 A160.1.22 2.60 2.40 4.0

100.0 A160.2.22 6.70 6.50 –

N 71.0 A160.2.42 5.00 4.80 5.0

P 56.0 A160.2.42 3.70 3.60 3.5

Q 40.0 A160.2.42 2.80 2.73 2.8

R 31.5 A160.2.42 2.00 1.98 2.0

S 22.4 A160.2.42 1.50 1.46 1.5

T 16.0 A160.2.66 1.06 1.03 1.0

U 12.5 A160.2.66 0.77 0.75 0.7

V 9.0 A160.2.66 0.62 0.60 0.6

W 7.1 A160.2.66 0.45 0.44 0.5

D 414.0 A160.1.08.BO

28.60 23.10 40.0

E 414.0 A160.1.08.BO

28.60 23.10 40.0

F 345.0 A160.08.14 20.90 14.50 35.0

G 255.0 A160.08.14 12.60 8.90 20.0

H 102.0 A160.08.14 7.20 5.80 14.0

190.0 A160.1.14 17.50 16.10 –

J 56.0 A160.08.14 4.30 3.50 10.0

186.0 A160.1.14 10.50 9.70 –

K 20.0 A160.08.22 3.00 2.50 6.0

160.0 A160.1.22 7.40 6.80 –

L 20.0 A160.08.22 2.00 1.62 5.0

103.0 A160.1.22 4.90 4.50 –

M 76.0 A160.1.22 3.80 3.50 6.0

N 69.0 A160.1.22 3.20 2.90 4.0

P 69.0 A160.2.42 5.70 5.50 5.0

Q 42.0 A160.2.42 3.30 3.22 3.0

R 25.0 A160.2.42 2.30 2.24 2.0

T 22.5 A160.2.66 1.41 1.37 1.3

Pneumatic Actuator Type A 160

Operating Instructions

Emerson

reserves the right to change the contents without notice page 10

8.2 Characteristics Safety Valves VSE / VSR

The pneumatic actuators are recommended for a supplementary loading of at least 30% at

6 bar control air pressure. Opening of the safety valve at 85% of the set pressure or less are

possible at 6 bar control air pressure. Pneumatic actuators for higher supplementary loadings

are also available.

8.3 Characteristic Safety Valves Series S DIN

The pneumatic actuators are recommended for a supplementary loading of at least 30% at

6 bar control air pressure. Opening of the safety valve at 85% of the set pressure or less are

possible at 6 bar control air pressure. Pneumatic actuators for higher supplementary loadings

are also available.

Orifice Max. set Pneumatic Constant Drive with return spring

letter pressure drive required below

pmax [bar] type K1

p [bar]

Orifice Max. set Pneumatic Constant Drive with return spring

letter pressure drive required below

pmax [bar] type K1

p [bar]

Notes

1) Pneumatic actuator only for supplementary

2) Factor for the determination of the

supplementary loading

3) Factor for the determination of the set

pressure

Notes

1) Pneumatic actuator only for

supplementary loading

2) Factor for the determination of the

supplementary loading

3) Factor for the determination of the set

pressure

Sempell Pneumatic Drive Type A 160 IOM Owner's manual

Sempell Pneumatic Drive Type A 160 IOM Owner's manual

Sempell Pneumatic Drive Type A 160 IOM Owner's manual

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