app manual

7/29/2019 APP Manual

http://slidepdf.com/reader/full/app-manual 1/32

OPERATION & MAINTENANCE MANUALMODEL APP

PISTON PNEUMATIC ACTUATOR



page TABLE OF CONTENTS

I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

II. Actuator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

III. Actuator Technical Specication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . 15XV. 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



page INTRODUCTION

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, ow 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 servicein 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.



page ACTUATOR TECHNICAL SPECIFICATION

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

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

3. API Classication 6A

4. Trim (API 6A Material Class) BB

5. Temperature Classication 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



page

MODEL APP PISTON PNEUMATIC ACTUATORACTUATOR SIZES, DIMENSIONS, WEIGHT & VOLUME

AB

FC

D

E

G

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

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

Note: Swept volumes represent the maximum actuator stroke.



page

ORDERING INFORMATION

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_______________________________________________________________________________________

• Certication / Specication_______________________________________________________________________

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: ____________________________________________________________________



page

MODEL APP PISTON PNEUMATIC ACTUATORCONTROL PRESSURE EQUATIONS

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)

VALVE WORKING PRESSURE

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

BORESIZE

APP1300x030 APP1300x030

134 psi 198 psi

113 ⁄ 16 .013 x wp + 3 psi .013 x wp + 3 psi

APP1800x030 APP1800x030

72 psi 107 psi

.007 x wp + 2 psi .007 x wp + 2 psi

APP1300x030 APP1300x030 APP1300x030 APP1800x030

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

APP1800x030

82 psi

.008 x wp + 2 psi




APP1800x030 APP2000x030

92 psi 107 psi

.009 x wp + 2 psi .007 x wp + 2 psi




31 ⁄ 16 APP1800x040 APP2000x030

63 psi 103 psi

.012 x wp + 3 psi .010 x wp + 2 psi

APP1300x040 APP1300x040 APP2000x040

112 psi 184 psi 153 psi

.036 x wp + 4 psi .036 x wp + 4 psi .015 x wp + 3 psi

APP1800x040

41 ⁄ 16 97 psi

.019 x wp + 2 psi

APP2000x040

78 psi

.015 x wp + 2 psi

APP1300x050 APP1800x050

178 psi 152 psi

51 ⁄ 8 .058 x wp + 4 psi .030 x wp + 2 psi

APP1800x050 APP2000x050

93 psi 123 psi.030 x wp + 2 psi .024 x wp + 3 psi

APP1800x070

71 ⁄ 16 164 psi

.054 x wp + 2 psi

APP2000x070

135 psi

.044 x wp + 3 psi



page

CONTROL PRESSURE EQUATIONS

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 specications such as size, maximum rated working pressure,

projected shut-in pressure and maximum ow line pressure.

DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY

Determine maximum ow line pressure in gate valve.

What is the available hydraulic pressure supply at site?

Multiply the maximum ow 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.



page

APP SIZING CHART

R e q u i r e d

A c t u a t o r C o n t r o l P r e s s u r e

( p s i )

t o

O p e n

V a l v e

a t F

u l l D i f f e r e n t i a l

Valve Working Pressure (WP) x 1000 psi

113/16 Nominal Gate Valve

170160

150

140

130

120

110

110

90

80

70

60

5040

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P 1

3 0 0 x 0

3 0 C p

= . 0 1 3

x w p +

3 p s i

A P P 1 8 0

0 x 0 3 0 C

p = . 0 0 7

x w p + 2

p s i

R e q u i r e d

A c t u a t o r C o n t r o l

P r e s s u r e

( p s i )

t o

O p e n

V a l v e

a t F u l l D i f f e r

e n t i a l



170

160

150

140

130

120

110

110

90

80

70

60

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P 1

3 0 0 x

0 3 0 C

p = . 0 1 4

x w p

+ 3 p

s i

A P P 1

3 0 0 x

0 3 0 C

p = . 0 1 3 x w p

+ 3 p s i

A P P 2 0

0 0 x 0 3 0

C p = . 0

0 8 x w p

+ 2 p s i



page 1

APP SIZING CHART

R e q u i r e d


( p s i )

t o

O p e n

V a l v e

a t F




170160

150

140

130

120

110

100

90

80

70

60

5040

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P 1

3 0 0 x

0 3 0 C

p = . 0 1 7

x w p

+ 3 p

s i

A P P 1 8 0

0 x 0 3 0

C p = . 0

0 9 x w p

+ 2 p s i

A P P 2 0 0

0 x 0 3 0 C

p = . 0 0 7

x w p + 3

p s i

R e q u i r e d


P r e s s u r e

( p s i )

t o

O p e n

V a l v e


e n t i a l


31/8 – 31/16 Nominal Gate Valve

170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P

1 3 0

0 x 0 3

0 C p

= . 0 2 4

x w p + 4 p s i

A P P 1

8 0 0 x 0

3 0 C p

= . 0 1 2

x w p +

2 p s i

A P P 2 0

0 0 x 0 3

0 C p =

. 0 1 0 x

w p + 3

p s i



page 1

APP SIZING CHART

R e q u i r e d


( p s i )

t o

O p e n

V a l v e

a t F



41/16Nominal Gate Valve

170160

150

140

130

120

110

100

90

80

70

60

5040

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P

1 3 0

0 x 0 4

0 C p

= . 0 3 5

x w p

+ 4 p s i

A P P 1 8

0 0 x 0 4

0 C p = .

0 1 9 x

w p

+ 2 p s i

A P P 2

0 0 0 x

0 4 0 C

p = . 0 1 5

x w p

+ 3 p

s i

R e q u i r e d


P r e s s u r e

( p s i )

t o

O p e n

V a l v e


e n t i a l



170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P

1 3 0

0 x 0

5 0

C p

= .

0 5 8

x w p

+ 4 p s i

A P P

1 8 0

0 x 0 5

0 C p

= . 0 3 0

x w p

+ 2 p s i

A

P P 2 0 0

0 x 0 5

0 C p

= . 0 2 4

x w p + 3

p s i



page 1

APP SIZING CHART

R e q u i r e d


( p s i )

t o

O p e n

V a l v e

a t F



71/16Nominal Gate Valve

170160

150

140

130

120

110

100

90

80

70

60

5040

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P

1 8 0 0

x 0

7 0

C p

= .

0 5 4

x w p

+ 2 p s i

A P P

2 0 0 0

x 0

7 0

C p

= .

0 4 4

x w p

+ 3 p s i



page 1

ACTUATOR VALVE SIZING CHART PROCEDURE

R e q u i r e d

A c t

u a t o r C o n t r o l P r e s s u r e

( p s i )

t o

O p e n

V a l v e

a t F u l l D i f f e r e n t i a l


31/8 – 31/16 Nominal Gate Valve

Y A

X I S

170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 150 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

A P P

1 3 0 0

x 0 3 0

C p =

. 0 2 4

x w p + 4 p

s i

A P P 1

8 0 0 x 0

3 0 C p

= . 0 1 2

x w p +

2 p s i

A P P 2 0

0 0 x 0 3

0 C p =

. 0 1 0 x

w p + 3

p s i

1. To select the proper actuator size and control pressure you must rst determine the

gate valve bore size and the maximum working pressure of the valve.

2. Now determine the maximum owing and shut in pressure for production.

3. Determine the available hydraulic control supply pressure at location.

4. Using the appropriate gate valve bore chart, nd the y-axis location and draw a vertical line to the top of the chart.

5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point denes 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.



page 1

PARTS LIST

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 specic differences are usually

limited to the design of the bottom of the bonnet and operating stem.

7

3

9

8

4

10

11

12

13

14

18

32

23

41

20

34

33

36

38

1

2

5

6

16

17

22

21

19

15

24

30

29

28

27

35

37

# DESCRIPTION

1 Top Shaft

2 Seal Retainer (AK)

3 Retainer Ring (AK)

4 Rod Wiper (AK)

5 Polypak™ Seal (AK)

6 Wear Bearing (AK)

7 Top Plate Assembly

8 Shear Ring

9 O-Ring (AK)

10 Retainer Nut

11 O-Ring (AK)

12 O-Ring (AK)

13 Wear Bearing (AK)

14 Piston Assembly

15 O-Ring (AK)16 Spring Retainer Plate

17 Spring

18 Down Stop

19 Lock Ring

20 Bonnet Ring

21 Pressure Relief Device (AK)

22 Housing Bolts (AK)

23 Cylinder

24 Lower Plate Assembly

25 Actuator Assy ID Tag (NS)

26 Drive Screw (NS)

27 Attachment Bolt28 Locking Screws (AK)

29 Cam Clamp

30 Washer (AK)

31 Caution Tag (NS, AK)

BONNET

32 Packing Retainer

33 O-Ring (Inner) (BK)

34 O-Ring (Outer) (BK)

35 Test Fitting

36 Polypak™ Seal (BK)

37 Bonnet Stem

38 Bonnet

39 Bonnet Assembly ID Tag (NS)

40 Drive Screw (NS)

41 Drift Shims

(NS) = Not Shown

(AK) = Actuator Repair Kit Items

(BK) = Bonnet Repair Kit Items



page 118. 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.

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 at 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 tting 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 xture 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 Teon tape or Teon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate.

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

33. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will beserialized and documented by certied personnel.



page 1MODEL APP REMOVAL AND REPLACEMENT OF PISTON ACTUATORTOP 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 threadedboss. 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.



page 1APP MAIN ACTUATOR ASSEMBLY

The following outlines the assembly of the Pneumatic Piston Actuator in rst sub assemblies and then into a nal

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

ying 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 at surface.

2. Place the housing on at 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 nish 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, at 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 at 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

at 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 nish. 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).



page 117. Install (Seal Retainer #2) into bore of top plate. Push down to contact (Polypak™ Seal #5).

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 at 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 nish 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 t 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 xture 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 toa 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 Teon tape or Teon liquid on NPT threads. Install plastic 12-NPT plug in opposite hold in top plate.

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

38. The actuator has been assembled and tested. Refer to the appropriate marking procedure. The actuator will be

serialized and documented by certied personnel.



page 2

PISTON ACTUATOR EXPLODED VIEW



page 2

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 ying 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 anymetal shavings or bits of residue from wrench operation.

8. Install a (Test Fitting #35) in the tapped hole in the Bonnet ange

and tighten tting securely. Use pipe tape or liquid (Teon).

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

ange 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.

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

on size, working pressure and manufacturer.



page 2

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.

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 thebonnet 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.

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 sufcient

control pressure to the actuator to unseat the re seal. This will prevent damage to the

re 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.



page 2ACTUATOR TO BONNET & GATE VALVE ASSEMBLY

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

at 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 rotatewhile 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.

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

Teon tape or Teon liquid, tighten securely. Wipe off excess liquid if used.

11. Apply (Actuator Assembly ID Tag #25) using 2 (Drive Screws #26) to

(Lower Plate Assembly #24). Location should not interfere with exhaust

holes or bolt holes. Contour nameplates to t outer diameter of housing.

Eliminate any sharp edges that may cause injury to personnel.



page 2

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 2

ADD SHIMS REMOVE SHIMS

GATE

GATE



page 2FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING

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 beinjurious 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: Removebolts 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.

10. Remove (Packing Retainer #32), rotate in a counterclockwise direction, using a pipe wrench. Caution: Be careful

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.

12. Clean packing bore and grease generously. Install (Bonnet Packing #36) with o-ring energizer facing down toward

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 rmly.

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).



page 218. 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

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 actuatorinlet nipple. Attach all electrical and fusible accessories to top of actuator if applicable.



page 2SERVICING ARRAY MODEL APP ACTUATORS

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 ofpressurized uids 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 conrm 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. DONOT 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 nished prior to installation or inspection of any new or used component. A suitable uid 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. Caution: failure to follow the procedures given in this manual may result in equipment damage, operating

problems and/or personal injury.



page 2TESTING

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 certied 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 ve (5) years or

when leakage occurs



page 3TROUBLESHOOTING

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

Insufcient pressure incontrol 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

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

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.

Check threads on bonnet and pull

to full extension properly back-seating

system.

Check thread engagement on bonnet

stem and downstop for burrs, nicks,

dings and debris. Check size and threadpattern for proper engagement.

Remove actuator and tighten downstop

to bonnet stem.


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


manual. Remove bonnet as per bonnet

manufacturer’s instructions and/or

drawings, re-assemble. This problem

only applies to certain valves.



page 3

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 topositive 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

Check for thread engagement betweendownstop and bonnet stem

Check regulator and control

pressure gauge

Gauge on top cap illustrates shut in

pressure/owing. Change actuator

control Actuator will not stroke after

psi increase.Contact factory or

double actuators.

Air will ow through four holes at baseof 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

TROUBLESHOOTING



page 3

MODEL APP PISTON PNEUMATIC ACTUATOR

ACTUATOR SPECIFICATIONS

Maximum Operating Pressure: 170 psi / (12 Bars)

Test Pressure: 255 psi / (18 Bars)

API Material Class: BBAPI 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-NLAPI Product Specication 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 otherwarranties. Whether express, implied or statutory, including,but not by way of limitation, any warranty of merchantabilityor tness for any particular purpose.

Array Products warrants to each original buyer of productsmanufactured by Array that such products are free from defectsin material and workmanship under normal use and service for aperiod of one (1) year from the date of shipment provided that nowarranty is made with respect to: Any product which has beenrepaired or altered in such a way in ARRAY’s judgment, as toaffect the product adversely; Any product which has, in ARRAY’s judgment, been subject to negligence, accident or improperstorage; Any product which has not been operated or maintainedin accordance with normal practice and in conformity withrecommendations and public specication of Array.

ARRAY’s obligation under this Warranty is limited to usereasonable efforts to repair, replace or, at it’s option, refundingthe purchase price. The cost of labor for installing a repair orreplacement product shall be borne by Purchaser. Replacementparts provided under the terms of this Warranty are warranted forthe remainder of the warranty period of the products upon whichthey are installed to the same extent as if such parts were originalcomponents thereof. Warranty services provided there under donot assume any liability for damages caused by any delaysinvolving warranty service. For complete specication information,prices and name, address and telephone number of the ARRAYrepresentative nearest you, call or write to us at the address below.

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

ARRAY PRODUCTS

15900MoralesRoad,Houston,Texas77032

app manual

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