ASSEMBLY, ADJUSTMENT AND MAINTENANCE INSTRUCTIONS LEDEEN .
ASSEMBLY, ADJUSTMENT AND MAINTENANCEINSTRUCTIONSLEDEEN QUARTER TURN SUBSEA ACTUATORSMERMAID S-SERIES (SHALLOW WATER)TC9253
All the information contained in this manual is the exclusive property of Cameron. Any reproduction or use of the calculations, drawings, photographs, procedures or instructions, eitherexpressed or implied, is forbidden without the written permission of Cameron or its authorized agent.Initial Release 01February 2013Produced by Technical Publications, Houston, TX, USA 2013 CameronTC92532
TABLE OF CONTENTSGeneral .Preliminary Verifications on Receipt of the Material.6Storage and Preservation.6Actuator Lifting.7Assembly.11Actuator Adjustments.13Position Indicator Alignment.15Actuator Compensation System Filling and Check.15Verifications Before Deployment.16Maintenance.17Actuator Seals Replacement.17Bladder of Pressure Compensator Replacement.19Compensation Fluid Replacement.19Bladder Accumulators Low Pressure Liquid Separator.20I.Commissioning and Maintenance.20Spare Bladders.28I.II.III.IV.Technical Data.28Description.28Maintenance.29Compensation Fluid Replacement.29Safety.29I.II.Power Supply Connection.29Recommendations.29Remarks.30TC92533
NOTES:TC92534
GENERAL INFORMATION The actuators are delivered with plugged connections. The connectionsmust remain plugged if not utilized or must be re-plugged with the relevant plug orreconnected after any testing operation. The manual should be used by an experienced service technician or operator. Please keep this manual near the actuator so that it is available for future consultation. For questions or clarifications please contact www.c-a-m.com. To request new copies of the manual please contact www.c-a-m.com. The manufacturer reserves the right to modify, without prior notice, the characteristicsof the equipment described in this publication and is not obligated to update anyproducts and manuals previously rasedell'IOMIDRAULICIEPNEUMATICIEXPLANATION OF WARNING SYMBOLS (where applicable)TC9253Before carrying out any operation on the actuator, the electric power supply(if present) must be shut-off.Risk of explosion: before carrying out any operation on the actuator, theactuator must be isolated from the hydraulic supply source.Before carrying out any operation on the actuator, the control group (ifpresent) must be discharged from the pressure therein trapped; particularcare shall be taken on storage tanks and pressure filters.Every operation on the actuator must be performed by qualified personnelequipped with safety clothes and devices (gloves, helmet, glasses, etc.).During the operation on the actuator, the operator must pay attention tothe presence of liquids potentially noxious for the health and theenvironment.5
utilizzare la frase dell'IOM IDRAULICI E PNEUMI. PRELIMINARY VERIFICATIONS ON RECEIPT OF THE rning: The following steps must be completed on receipt of the material:1. Check the completeness of the supplies by referring to the packing list.2. Carry out a preliminary verification in order to ensure:a. the integrity of the material and the absence of damages;b. the integrity of the painting. if necessary, carry out the paint touch up byfollowing the instructions of the painting specification (please refer to thetechnical documentation);c. the presence of the plugs on all the hydraulic and (where present) electricalconnections.II. STORAGE AND PRESERVATIONWarning: A. Storage ConditionsFollow the instructions below if storage of the actuator is necessary: The actuator must be stored in a warehouse adequately protected against harmfulenvironment. The recommended ambient temperature is:minimummaximim 5 C (41º F) 40 C (104º F)B. Preservation ConditionsTo assure proper operation of the equipment after installation, the followingprocedures must be performed during storage: Keep the actuators lifted from the ground. Protect all unpainted parts with grease. In case the actuator is provided with a pressure compensating system, do notexpose the actuator to direct sunlight in order to avoid any overpressure inthe same system.Note: Before installing the actuator, perform one complete cycle (opening and closing) andverify that it works correctly.TC92536
III. ACTUATOR LIFTINGWarning: Important: These instructions refer to the lifting of the actuator only, not assembled on thevalve.Do not attempt to lift the actuator-valve assembly by using the lifting points ofthe actuator.The lifting equipment consists of commercial chains and slings of adequate dimensionsaccording to the weight of the actuator. Please refer to the Assembly Specificationdocument provided.Refer to the following tables for standard commercial equipment.TC92537
LIFTING DEVICES MAXIMUM nn2 armsCMU/tonn1 arm1.121.523.155.3811.212.51521.231.50 ß 45 0 α 90 45 ß 60 90 α 120 0 ß 45 0 α 90 45 ß 60 90 α 120 Factor 1.4Factor 1.0Factor 2.1Factor 1.545671.72.2434.75811.8171922.431.547.5Figure 1ChainsTC9253CMU/tonn3 & 4 arms8
Load in %100 %200 %140 %from 7 to 45 80 %100 %from 45 to 60 C.M.U.Width1T3010002000140080010001,5 T50150030002100120015002T60200040002800160020002,5 0800010 T30010,00020,00014,000800010,00015 T24015,00030,00021,00012,00015,00020 T30020,00040,00028,00016,00020,000Figure 2SlingsTC92539
Notes: In order to prevent any damage to the actuator equipment, before starting thelifting operations, please double check that the lifting tools are away from the controlpanel (if present) and avoid any interference with the ancillaries, like the pressurecompensator and relevant connecting tubing.Lift the actuator by utilizing the suitable lifting points (indicated in the followingdrawings with the # symbol).A. Double Acting ActuatorsB. Spring Return ActuatorsTC925310
IV. ASSEMBLYA. Assembling Actuator onto the ValveWarning: Note: No special tools are required for these operations, only Allen wrenches, hexagonalassemblingwrenches and torquewrenches of the required sizes.1. Clean the top flange of the valve.2. Lubricate the shaft of the valve with oil or grease.3. Place the actuator in the same position of the valve supplying pressure to thehydraulic cylinder.4. Lift the actuator by following the instructions in Section IV.5. Clean the actuator flange.6. Install the O-ring on the provided groove after having properly cleaned andlubricated the seal.7. Connect the valve shaft inside the stem adapter and lower the actuator on thevalve.8. Tighten the nuts between the spool piece flange and the valve one.9. The torque to apply to the bolts is as per the table STC1325 provided in TechnicalDocumentation.Warning: For actuators provided with compensation system already filled (see Section VII onpage 15), open the stop valve placed near the adapter piece (indicated inWarningfigure 3).togliere la virgolaFigure 3TC925311
Non Teflon-Coated Tie-RodsTie RodTypePitchmmM8M 10M 12M 14M 16M 18M 20M 22M 24M 27M 30M 33M 36M 39M 42M 45M 48M 52M 56M 60M 64M 68M 72M 76M 80M 85M 90M 95M 100M 105M 110M 120M ,004,004,004,004,006,004,004,006,00Teflon-Coated Tie-RodsTightening – Nm ( 5%)Mat. (1) Mat. (2) Mat. 110391345Tie RodTypePitchmmM8M 10M 12M 14M 16M 18M 20M 22M 24M 27M 30M 33M 36M 39M 42M 45M 48M 52M 56M 60M 64M 68M 72M 76M 80M 85M 90M 95M 100M 105M 110M 120M ,004,004,004,004,006,004,004,006,00Tightening – Nm ( 5%)Mat. (1) Mat. (2) Mat. 10391345Note: Column Mat.(1) applicable to the following materials:A193 87M, A320 L7M, A453 Gr.6608, 8S 4882, A193 87 ( M 100)Column Mat.(2) applicable to the following materials:A320 L7, A320 L43, A193 87, 39NiCrMo3 ( M 100)Column Mat.(3) applicable to the following materials:A 193 88 Classe 2 ( M 39)Load required for the hydraulic pre-tightening is calculated based on the stress applied to the tierod(% Sn). This load shall be increased on the base of the load lost during the pre-tightening (Cp).Cp value reported in the table is for reference only and should be calculated again before everyapplication.TC925312
V. ACTUATOR ADJUSTMENTSWarning: Note: No special tools are required for these operations, only Allen wrenches and hexagonalwrenches of the required sizes.A. End Stops AdjustmentThe actuator is shipped with a preliminary adjustment, but not based on the specific valvestroke. If it is necessary to change the adjustment, proceed as follows:1. Loosen the locking nuts counter-clockwise for only a 1/4 turn to avoid leaking ofthe compensating fluid, then rotate the dowels to the required position.2. Tighten the locking nut when completed.a. For GS Actuators: on the actuator frame:By rotating the dowels clockwise, the angular stroke is reduced; by unscrewing thedowels the angular stroke is increased.Note: In case of spring return actuators, before adjusting the end stop relevant to the cylinder,it is necessary to pressurize the same with low pressure in order to reduce the pressuredeveloped by the spring thrust against the end stop to be adjusted.TC925313
b. For SY Actuators: on the spring container and the cylinder for spring return actuators: on the cylinder and the frame for double acting actuators:by unscrewingBy rotating the dowels clockwise, the angular strokeis reduced; by unscrewing the dowelsthe angular stroke is increased.Note: In case of spring return actuators, before adjusting the end stop relevant to the cylinder,it is necessary to pressurize the same with low pressure in order to reduce the pressuredeveloped by the spring thrust against the end stop to be adjusted.developedTC925314
utilizzare la frase dell'IOM IDRAUVI. POSITION INDICATOR ALIGNMENTVerify the correct indication of the actuator position by the local position indicator:“OPEN” when the actuator is in open position.“CLOSED” when the actuator is in closed position.utilizzare la frase dell'IOM IDRAULICI E ll'IOMIDRAULICIIDRAULICIEEPNEUMATICIPNEUMATICIVII. ACTUATOR COMPENSATION SYSTEM FILLING AND CHECKWarning: A. Compensation System FillingThe compensation system filling has to be carried out in accordance to procedureUTP-SM-50, last revision, paragraph 3, provided in the Assembly Specificationdocument.B. Compensation System Filling CheckThe check of the filling of the compensation system has to be performedin accordance to the above mentioned procedure UTP-SM-50, last revision,paragraph 4.TC925315
VIII. VERIFICATIONS BEFORE DEPLOYMENTWarning: Note: No special tools are required for these operations, only Allen wrenches and hexagonalwrenches of the required sizes.A. Functional VerificationCarry out two complete strokes of the actuator with the hydraulic supply and(where applicable) with the spring in order to verify that: the operation is smooth throughout its stroke; there is no evidence of stick-slip or mechanical restraint; the indication of the local position indicator is correct. If not, carry out the positionindicator alignment as described in the relevant paragraph; (where applicable) the operation of the limit switches is correct.If it is necessary, purge the air from the cylinder by loosening the plug(s) placed on top ofthe flange(s) (see figure 4) and by performing some opening/closing operations until onlyoil comes out from the hole(s). Then, tighten the plug(s).Figure 4TC925316
utilizzare la frase dell'IOM IDRutilizzare la frase dell'IOM IDRAULICI EIX. MAINTENANCEWarning: Note: No special tools are required for these operations, only Allen wrenches and hexagonalwrenches of the required sizes.A. Ordinary MaintenanceMaintenance should not be required on the actuator when: the actuator has been properly stored before installation; the installation onto the valve has been carried out correctly; the adjustments have been performed correctly. The compensation system fillinghas been carried out in accordance to the instructions, where applicable;the deployment has been performed correctly.B. Special Maintenance Any operation of special maintenance of the actuator has to be performed after havingbrought the actuator to the surface. In case the actuator is provided with compensation system and it is necessary todisassemble it from the valve, close the stop valve placed near the adaptor piece.X. ACTUATOR SEALS REPLACEMENTWhen the seals need to be replaced (for example, in case of leakage), it is necessary tocarry out the following operations:1. The compensation system (if present) must be emptied before proceeding with theactuator disassembly.2. Check, before re-assembly, that the seats of the seals are clean and lubricated.A. FrameThe seals to be replaced in the frame are (refer to figure 5): the seals between frame and cover (item 90); the seals between frame and cylinder (item 320); the seals between frame and end stroke cover (item 320, for SY doubleacting actuators), between frame and side cover (item 320, for GS doubleacting actuators) and between frame and spring container (item 320,for spring return actuators).TC925317
Figure 5B. CylinderThe following seals are to be replaced in the cylinder (refer to figure 6): the piston O-ring (item 60); the O-rings (items 70 & 210) between liner and flanges; the rod O-ring (item 80); the O-ring (item 550) between screw and end flange; the O-ring (items 560 & 570) between cap and screw.Figure 6TC925318
C. End Stroke Cover (only for SY double acting actuators)The seals to be replaced in the end stroke cover are (refer to figure 7): the O-ring (item 520) between screw and flange; the O-ring (item 530) between cap and screw.Figure 7XI. BLADDER OF PRESSURE COMPENSATOR REPLACEMENTThe replacement of the bladder of pressure compensator has to be carried out inaccordance to the manufacturer’s instructions.XII. COMPENSATION FLUID REPLACEMENT The compensation system fluid replacement has to be carried out in accordance to theprocedure UTP-SM-50, last revision, paragraph 3 provided in the Assembly Specificationdocument. After the compensation system fluid replacement, perform the compensation systemcheck in accordance to the above mentioned procedure, UTP-SM-50, last revision,paragraph 4.TC925319
BLADDER ACCUMULATORS LOW PRESSURE LIQUID SEPARATORI. COMMISSIONING AND MAINTENANCEA. Delivery Conditions Depending on the size and quantity ordered, the bladder(s) are shipped in boxes,cartons, pallets or wooden boxes on request. Unless otherwise required, certificates and documentation are provided together withthe accumulators.B. Handling The original packaging is suitable for handling and storage. Where necessary, suitable lifting equipment should be used to support the weight ofthe accumulators. Protect the packaging from impact and handle it with care.C. Storage During storage in the warehouse, leave the product in its original packaging and keepit away from heat sources and naked flames. The storage temperature should bebetween 10 C and 40 C. For six months of storage, make sure that lubrication fluid inside is compatible withbladder polymer.TC925320
After six years of storage, it is essential to replace all elastomeric parts beforecommissioning.The following actions are strictly forbidden: welding, riveting or screwing any item of the accumulator; engraving or permanently stamping the surfaces of the accumulator shell and / orcarrying out other operations that could affect or change the mechanical properties ofthe accumulator; using the accumulator as a structural element. It should not be subjected to stresses orloads; changing the data of the nameplate and/or accumulator without the permission of themanufacturer; or using a (dangerous) fluid of Group 1 with equipment designed and manufacturedfor fluids of Group 2.D. InstallationBefore installation, a visual check must be performed to verify that the accumulator hasnot suffered any damage during shipping/handling.1. Verify that the requested type matches what is stamped on the nameplate. Theaccumulators may be installed in any position (horizontal or vertical) and thenameplate must be visible. Proceed carefully with the assembly so that no abnormalforce affects the pipes connected directly or indirectly to the accumulator. Toaccomplish this, we recommend the use of supporting components and alsofastening to avoid the transmission of vibrations.2. Make sure that the accumulator is connected to the hydraulic circuit by suitableconnection devices.3. Make sure the fluid is compatible with the elastomer of the bladder. Check that themaximum allowed accumulator pressure is equal to or greater than the one of thehydraulic circuit
LEDEEN QUARTER TURN SUBSEA ACTUATORS MERMAID S-SERIES (SHALLOW WATER) TC9253. . duction or use of the calculations, drawings, photographs, procedures or instructions, either expressed or implied, is forbidden without the written permission of Cameron or its autho- . actuator must be isolated from the hydraulic supply source.
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