DeZurik G-SERIES User manual

DeZURIK, Inc. Sartell, Minnesota USA | Phone: 320-259-2000 | www.dezurik.com | info@dezurik.com

DEZURIK CYLINDER

OPERATED

G-SERIES ACTUATOR

USED ON PEC ECCENTRIC VALVES

Instruction

D10022

August 2012

DeZURIK

Cylinder Operated G-Series Actuator

Instructions

These instructions provide information about G-Series Cylinder Actuators. They are for use by

personnel who are responsible for installation, operation and maintenance of G-Series Cylinder

Actuators.

Safety Messages

All safety messages in the instructions are flagged with an exclamation symbol and the word Caution,

Warning or Danger. These messages indicate procedures that must be followed exactly to avoid

equipment damage, personal injury or death. Safety label(s) on the product indicate hazards that can

cause equipment damage, personal injury or death. If a safety label becomes difficult to see or read, or

if a label has been removed, please contact DeZURIK for replacement label(s).

Personnel involved in the installation or maintenance of valves should be constantly alert to

potential emission of pipeline material and take appropriate safety precautions. Always wear

suitable protection when dealing with hazardous pipeline materials. Handle valves, which

have been removed from service with the assumption of pipeline material within the valve.

Inspection

Your G-Series Cylinder Actuator has been packaged to provide protection during shipment; however, it

can be damaged in transport. Carefully inspect the unit for damage upon arrival and file a claim with the

carrier if damage is apparent.

Parts

Recommended spare parts are listed on the assembly drawing. These parts should be stocked to

minimize downtime.

Order parts from your local DeZURIK sales representative, or directly from DeZURIK. When ordering

parts, please include the 7-digit part number and 4-digit revision number (example: 9999999R000)

located on the data plate attached to the valve assembly. Also include the part name, the assembly

drawing number, the balloon number and the quantity stated on the assembly drawing.

DeZURIK Service

DeZURIK service personnel are available to install, maintain and repair all DeZURIK products.

DeZURIK also offers customized training programs and consultation services.

For more information, contact your local DeZURIK sales representative or visit our website at

www.dezurik.com.

DeZURIK

Cylinder Operated G-Series Actuator

August 2012 Page 3 D10022

Table of Contents

Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Air Supply - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Actuator Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4

Adjusting Position Stops

Adjusting the Open Position Stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Adjusting the Closed Position Stop - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Removing Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

Installing Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

Removing Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Installing Cylinder - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

Disassembling Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Reassembling Actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14

Changing Mounting Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Mounting Actuator in 60° Increments on 4–20" (100–500mm) Valves and 90°

Increments on 24–36" (600–900mm) Valves - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Mounting Actuator in 30° Increments on 4–20" (100–500mm) Valves Only - - - - - - -

Mounting Actuator in 45° Increments on 24–36" (600–900mm) Valves Only - - - - - - 17

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

DeZURIK

Cylinder Operated G-Series Actuator

D10022 Page 4 August 2012

Description

The G-Series Cylinder Actuator is a totally enclosed, quarter turn, pneumatic operated actuator. A 2"

(50mm) square nut on top of the actuator is provided for manual operation. It is supplied with a single

cylinder, and single or double booster cylinders dependent on application.

Air Supply

The supply pressure to the cylinder should be between 50 and 100 psi (344 and 689 kPa).

Lubrication

The G-Series Cylinder Actuator has been lubricated at the factory and requires no routine lubrication. If the

actuator is disassembled, lubricate the rack, rack guide, gear sector and bearings using one of these lubricants:

- Keystone Zeniplex-1 (recommended)

- Amoco Amolith Grease #1-EP (alternate)

- Amsoil GHD (alternate)

- Mobil Mobilux EP 1 (alternate)

- Petro-Canada Vultrex MPG EP 1 (alternate)

- Shell Alvania EP 1 (alternate)

- Texaco Multifak EP 1 (alternate)

If the cylinder is disassembled, it must be lubricated as described in the cylinder instructions.

Actuator Identification

The G-Series Cylinder Actuator is available in three sizes: G6, G12 and G16. See Figure 1 for actuator

identification.

Figure 1 - Actuator Identification

To determine the actuator size, measure the diameter of the cover - see Figure 1 and Table A. To

determine the cylinder size, measure the diameter of the cylinder - see Figure 1 and Table B.

Table A: Actuator Identification

Table B: Cylinder Identification

Actuator

∅“A”

Cylinder

∅“B”

205

4.5

115

G12

390

6.5

165

G16

485

8.5

215

C10

10.5

265

C12

12.5

320

DeZURIK

Cylinder Operated G-Series Actuator

August 2012 Page 5 D10022

Adjusting Position Stops

The G-Series Cylinder Actuators have both open and closed position stops. See Figure 2 for

position stop identification.

Figure 2 – Position Stops

The position stops are factory set and do not require adjustment unless the actuator has been

disassembled or actuator orientation has been changed.

Adjusting the Open Position Stop

On actuators without booster cylinders, the open position stop is located in the end of the extension cap

opposite the cylinder. On actuators with booster cylinders, the open position stop is located in the end

of the power cylinder. See Figure 2.

1. Open the valve and loosen the Open Position jam nut.

2. Adjust the Open Position set screw to the proper position.

3. Lock the Open Position set screw in place with the jam nut.

DeZURIK

Cylinder Operated G-Series Actuator

D10022 Page 6 August 2012

Adjusting Position Stops (Continued)

Adjusting Closed Position Stop

On actuators without booster cylinders, the closed position stop is located in the end of the cylinder. On

actuators with booster cylinders, the closed position stop is located in the end of the booster cylinder.

See Figure 2.

Valves can be mounted with Direct or Reverse pressure.

Direct Pressure - When the higher pressure is at the end opposite the seat. See Figure 3.

Reverse Pressure - When the higher pressure is at the seat end of the valve. See Figure 3.

Figure 3 – Pressure Direction

1. Discontinue flow and relieve pipeline pressure.

2. Back out the Closed Position set screw about 1½ turns.

3. Close the valve with the pressure specified in Table C and Table D for the appropriate size and

pressure direction—See Figure 3.

Direct Pressure (higher pressure is at end opposite the seat), use the cylinder pressure

specified in Table C and Table D for 25 psi (172 kPa) reverse pressure drop.

Reverse Pressure (higher pressure is at seat end of valve), use the cylinder pressure specified

in Table C and Table D for the amount of reverse pressure drop in your pipeline.

The pressure in Table C and Table D will provide tight shut off or minimum leakage (depending on

pressure drop) with maximum plug life. If the reverse pressure drop in the pipeline is unknown, set

closing pressure for the maximum pressure drop. Reset the closing pressure as soon as actual

pressure drop can be determined because the maximum setting decreases plug life.

4. Maintain pressure for 5 minutes to allow the plug to seat, then tighten the set screw in until it

comes into contact with the piston rod.

NOTE: Make sure the thread seal is positioned properly, and lock the setscrew in place with the jam nut.

DeZURIK

Cylinder Operated G-Series Actuator

August 2012 Page 7 D10022

Adjusting Position Stops (Continued)

Table C: Cylinder Closing Pressure - Reverse Pressure Drop*

Valve Size Actuator

Cylinder

Cylinder Closing Pressure

(For Direct Pressure Drop Use Same as 25# Reverse)

psi

172

kPa

50 psi

344

kPa

75 psi

517

kPa

100

psi

689

kPa

125

psi

861

kPa

4" (100mm)

G6-C4

103

110

117

124

G6-C6

6" (150mm)

G6-C4

144

165

186

213

220

G6-C6

8" (200mm)

G6-C6

137

151

172

193

—

G6-C8

103

110

—

G12-C6

103

G12-C8

10” (250mm)

G6-C6

206

248

—

G6-C8

117

137

—

G12-C6

103

124

144

165

179

G12-C8

103

G12-C10

12” (300mm)

G6-C6

282

—

G6-C8

158

—

G12-C6

144

179

206

241

—

G12-C8

103

117

137

151

G12-C10

G16-C8

103

117

G16-C10

G16-C12

14” (350mm)

G12-C6

179

234

—

G12-C8

103

131

165

193

—

G12-C10

103

124

—

G16-C8

103

124

144

—

G16-C10

—

G16-C12

—

G16-

C10B10

8 55 11 75 13 89 15 103 — —

16” (400mm)

G12-C6

220

—

G12-C8

124

165

—

G12-C10

110

131

—

G16-C8

124

151

179

—

G16-C10

103

117

—

G16-C12

—

G16-

C10B10

10 68 13 89 16 110 18 124 — —

G16-

C10B12

7 48 10 68 12 82 14 96 — —

* Reverse Pressure Drop: The pressures specified for reverse pressure drop will provide tight pressure shutoff or minimum

leakage with maximum plug life.

If a dead-tight shutoff with reverse pressure is required, contact DeZURIK

DeZURIK

Cylinder Operated G-Series Actuator

D10022 Page 8 August 2012

Adjusting Position Stops (Continued)

Table D: Cylinder Closing Pressure - Reverse Pressure Drop*

Valve Size Actuator &

Cylinder

Cylinder Closing Pressure

(For Direct Pressure Drop Use Same as 25# Reverse)

psi

172 kPa 50 psi 344 kPa 75 psi 517 kPa 100 psi 689 kPa

18” (450mm)

G12-C6

255

—

G12-C8

144

199

—

G12-C10

131

—

G16-C8

110

151

193

227

G16-C10

124

144

G16-C12

103

G16-C10B10

103

131

151

G16-C10B12

110

G16-C12B12

110

G16-C12B10B10

110

137

158

20” (500mm)

G12-C8

165

234

—

G12-C10

103

151

—

G16-C8

124

172

220

268

G16-C10

110

144

172

G16-C12

103

124

G16-C10B10

117

151

179

G16-C10B12

110

131

G16-C12B12

110

131

G16-C12B10B10

124

158

186

24” (600mm)

G16-C8

151

262

—

G16-C10

144

193

234

G16-C12

103

131

165

G16-C10B10

103

151

199

241

G16-C10B12

110

137

172

G16-C12B12

110

137

172

G16-C12B10B10

110

158

206

248

G16-C12B12B12

117

144

179

30” (750mm)

G16-C8

193

—

G16-C10

124

199

—

G16-C12

137

186

234

G16-C10B10

131

206

275

344

G16-C10B12

144

193

241

G16-C12B12

144

193

241

G16-C12B10B10

137

213

282

351

G16-C12B12B12

103

151

199

248

36” (900mm)

G16-C10B12

386

—

G16-C12B12

268

344

—

G16-C12B10B10

268

344

—

G16-C12B12B12

268

344

—

* Reverse Pressure Drop: The pressures specified for reverse pressure drop will provide tight pressure shutoff or minimum

leakage with maximum plug life.

If a dead-tight shutoff with reverse pressure is required, contact DeZURIK

DeZURIK

Cylinder Operated G-Series Actuator

August 2012 Page 9 D10022

Removing Actuator

When eccentric valves are mounted in a vertical pipeline, or mounted in a horizontal pipeline with the

plug stem horizontal, gravity can cause the plug to swing to a lower position in the valve body when the

actuator is removed. To avoid this problem, place the plug in the lowest position before removing the

actuator.

1. Discontinue flow, relieve pipeline pressure and close valve.

Accidental operation of power actuator can cause personal injury or equipment damage.

Disconnect and lock out power to actuator before servicing.

2. Disconnect and lock out the pneumatic power to prevent accidental operation of the actuator.

3. Scribe corresponding lines on the valve and actuator to help align them during installation.

4. If the valve is 4–20" (100–500mm), remove the lock nut, spring washers, wrenching nut and

pointer from the plug stud, then go to step 6.

5. If the valve is 24–36" (600–900mm), follow the steps below.

a. Loosen the #1 lockscrews about 6 to 8 turns. Loosen the #2 lockscrews about 3 turns. See

Figure 4

Figure 4 – 24-36” Valve Key and Lockscrew Arrangement

b. Using a soft hammer, tap the heads of the #1 lockscrews to loosen the keys.

c. Remove the four screws holding the wrenching nut to the gear sector, then remove

the stud locknut, spring washers and the wrenching nut with the keys attached.

Continue with step 6.

DeZURIK

Cylinder Operated G-Series Actuator

D10022 Page 10 August 2012

Removing Actuator (Continued)

This valve is a pressure vessel. On 4, 5, 6 and 10" (100, 125, 150 and 250mm) valves, the same

bolts hold both the actuator and the bonnet.

Removing the bolts on 4, 5, 6 and 10" (100, 125, 150 and 250mm) valves before relieving

pipeline pressure can result in personal injury or equipment damage.

Always relieve pipeline pressure before removing the actuator.

6. Remove the screws fastening the adapter to the valve. On the 4, 5, 6 and 10" (100, 125,

150 and 250mm) valves, these screws also hold the bonnet to the valve body.

7. Lift the actuator and adapter off the valve.

Installing Actuator

1. Place the valve in the position it was in when the actuator was removed.

NOTE: Normally this will be so the plug is in the lowest position in the valve body.

2. Line up the scribe marks on the valve and actuator made during actuator removal, then set the

actuator on the valve so that the valve shaft slides into the actuator gear sector.

3. Fasten the actuator adapter to the valve.

4. Slide the pointer and wrenching nut down the plug stud so that it rests on top of the gear sector;

the pointer should point to the correct valve position. If the valve is 24–36" (600–900mm), hold

the keys in position when you slide the wrenching nut over the plug stud and guide the keys into

the gear sector and stem slots. Then install the four screws fastening the wrenching nut to the

gear sector.

5. Place the spring washers on the plug stud as shown in Figure 5.

Figure 5 – Spring Washer Detail

6. Screw the lock nut down the plug stud until it is tight and the spring washers are completely

compressed, then back the nut off one full turn.

7. If the valve is 24–36" (600–900mm), tighten the #2 lockscrews and then the #1 lockscrews to

hold the keys in place; if the valve is 4–20" (100–500mm), go to step 8. See Figure 4

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