Emerson Shafer ECAT User manual

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

April 2021

Shafer ECAT

Emission Controlled Actuator Technologies

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

This page intentionally left blank

Notes

April 2021

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

Table of Contents

April 2021

iTable of Contents

Table of Contents

Section 1: Introduction

1.1 Scope............................................................................................................ 1

1.2 General Information...................................................................................... 1

1.3 Safety Information ........................................................................................ 3

1.4 Abbreviation Denitions ............................................................................... 4

Section 2: Installation

2.1 Preparation ................................................................................................... 5

2.2 Valve Preparation .......................................................................................... 6

2.3 Actuator Preparation..................................................................................... 6

2.4 Lifting the ECAT System ................................................................................ 7

2.5 Installing the ECAT Actuator on the Valve...................................................... 9

2.6 Setting the Stroke Limit Stops ....................................................................... 9

2.7 Hydraulic Fluid ............................................................................................ 10

2.8 Accumulator ............................................................................................... 10

Section 3: Electrical Connections

3.1 Main Electrical Connections ........................................................................ 13

3.2 Sealing Cable / Conduit Entries.................................................................... 13

Section 4: Set-up / Start-up Procedure

4.1 Preparation ................................................................................................. 14

4.2 Initial Check of the Unit ............................................................................... 15

4.3 Initial Connections ...................................................................................... 15

4.4 Initial Pre-Charge ........................................................................................ 15

4.5 Initial Reservoir Fill ...................................................................................... 15

4.6 Hydrostatic Pressure / Function Test............................................................ 15

4.7 Final Start-Up Procedure ............................................................................. 17

4.8 Optional Instrumentation ........................................................................... 17

Section 5: Troubleshooting

Troubleshooting ................................................................................................... 18

Section 6: Maintenance

6.1 Storage Procedures..................................................................................... 19

6.2 Service Interval ........................................................................................... 19

6.3 Lubrication Requirements ........................................................................... 19

6.4 Recommended Annual Inspection............................................................... 20

April 2021

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

Section 1: Introduction

Introduction

Section 1: Introduction

1.1 Scope

This manual is offered as a guide to be used along with locally approved and safe practices to install,

operate, service and maintain the ECAT system. Carefully follow the instructions in this manual and

make sure you install the system correctly and according to your requirements.

1.2 General Information

1.2.1 Overview

The ECAT is a self-contained, quarter-turn, valve actuator that combines proven technologies from

Emerson’s Valve Automation. The actuator has been designed for critical shutdown applications

where reliability is crucial.

The ECAT utilizes a hydraulic accumulator, pressurized with the pipeline gas, as a stored energy

source in order to actuate the actuator / valve open or closed. The self-contained system contains

an electric motor, gear pump, and reservoir. Pressure switches for alarming and return line hydraulic

ltration is available as an option.

1.2.2 Operation

After initial start-up and commissioning procedures have been accomplished, the electric driven

hydraulic pump will keep the power header and all accumulators pressurized to the appropriate

pressure with no intervention from operations personnel.

1.2.3 Maintaining Pressure

Any loss of pressure in the power header line or accumulators, whether caused by external leakage

or actuator movement, will cause the thermal-volume controller rod to move down. This movement

operates the motor control switch to the “Motor On” position, automatically starting the electric

driven hydraulic pump. The pump will run until the hydraulic uid in the power header line and all

accumulators has been replenished. When the header and accumulator have been lled, the thermal-

volume controller rod will rise and operate the motor control switch to the “Motor Off” position.

There is no need for the pump to be started or stopped by operations personnel.

1.2.4 Mechanically Operated Components

The only mechanically operated components on the ECAT system are the motor control switch

located on the thermal volume controller. This switch detects the position of the thermal-volume

controller and relays the information back to the control. The control then starts or stops a motor as

needed. The switch does not require adjustment or maintenance.

1.2.5 Relieving Pressure on the Fluid

High-pressure hydraulic uid can be safely routed back to the reservoir from the accumulator or

actuator units by opening the main accumulator Bypass valve located on the reservoir. Opening this

valve will allow the pressurized uid in the system to be common to the reservoir. This valve should

be opened slowly to prevent the high-pressure uid from foaming due to the velocity through the

hand valve. A hydraulic thermal relief valve is piped in parallel to this hand valve for the purpose

of relieving excess hydraulic pressure in case the control malfunctions or ambient temperature

conditions exceed design limits.

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

April 2021

Section 1: Introduction

Introduction

1.2.6 Fluid Level in Reservoir

The reservoir tank is provided with a stainless steel sight glass level viewer.

1.2.7 Functional Description

The following is a functional description of the ECAT System for valve actuators and a brief

explanation of the main components that make this ECAT system unique. Throughout this

explanation numbers which appear in parenthesis ( ) correspond to item numbers on Schematic

Diagram 11547-S.

The ECAT system provides energy for operation of valve actuators during normal operation as well as

emergency shutdown. This energy is hydraulic power stored in the Accumulator (76). When required,

the Accumulator (76) pushes the hydraulic uid into the power oil header line. The power oil header

line supplies the actuator power for operation.

The hydraulic uid leaving the valve actuator will pass through the return oil header line back into the

Oil Reservoir (60) creating a closed loop system.

The Accumulator (76) gets its power from high-pressure pipeline gas pushing on the accumulator’s piston.

The hydraulic uid, stored in the Accumulator (76), originates from the Oil Reservoir (60). Fluid

is drawn from the Oil Reservoir (60) and through the suction line by a Hydraulic Pump (67). The

hydraulic pump (67) forces the uid through the discharge line and into the Accumulator (76).

The ECAT system has one electric motor driven Hydraulic Pump (67). The pump is controlled by a

motor control switch operated by the Thermal-Volume Controller (77). While in operation, if the

Thermal-Volume Controller (77) moves a small amount actuating the Motor Start / Stop Switch (78)

to the “On” position, the electric motor driven Hydraulic Pump (67) will start to run. The pump will

operate until the Thermal-Volume Controller moves and actuates the Motor Start / Stop Switch (78)

to the “Off” position.

1.2.8 Product Attributes

• Easy installation – ECAT actuator is a totally self-contained system and designed for

compactness and adaptable to new or existing valves

• Designed for Bettis™ or Shafer hydraulic double-acting actuator and controls, including

the handpump

• Shafer™ hydraulic control technology

• Multiple input power options with either AC or DC

• Local open / close control

• Fast speed of operation to fail-safe position if required

• Accumulator suitable for hydraulic and natural gas service

• Operating pressures up to 2220 psi with standard components

April 2021

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

Section 1: Introduction

Introduction

1.3 Safety Information

Safety notices in this manual detail precautions the user must take to reduce the risk of personal

injury and damage to the equipment. The user must read these instructions in their entirety. Failure

to observe these safety notices could result in serious bodily injury, damage to the equipment, void

of the warranty. Take special notice of all tags, warning labels and instructions presented on the

actuator. These may provide more specic and signicant information regarding the actuator than

this general manual.

It is the responsibility of the user to ensure proper safety practices are utilized. Always take

necessary precautions and use proper protective equipment when dealing with compressed gasses,

compressed hydraulic uid, pinch points and electricity.

Safety notices are presented in this manual in three forms (Warning, Caution and Note) as follows:

! WARNING

Alerts user of potential danger; failure to follow the warning notice could result in serious personal

injury or death.

! CAUTION

Identies precautions the user must take to avoid personal injury or equipment damage.

NOTE:

Highlights information critical to the user’s understanding of the ECAT system installation or operation.

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

April 2021

Section 1: Introduction

Introduction

1.4 Abbreviation Denitions

Abbreviations used in this manual and their denitions are listed in the table below:

Table 1. Abbreviation Denitions

Abbreviation Denition

IOM Installation Operation Manual

ESD Emergency Shutdown

FS Fail-safe

DA Double-Acting

MAWP Maximum Allowable Working Pressure

MOP Maximum Operating Pressure

MCC Motor Control Center

LS Limit Switch

PS Pressure Switch

NC Normally Closed

NO Normally Open

CCW Counterclockwise

CW Clockwise

OL Overload

PPE Personal Protective Equipment

GA General Arrangement Drawing

SOV Solenoid Valve

NO Normally Open

NC Normally Closed

April 2021

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

Section 2: Installation

Installation

Section 2: Installation

2.1 Preparation

2.1.1 Delayed Usage

If for any reason the actuator is not to be installed immediately, Emerson Process Management

recommends the following procedures. Failure to comply, with recommended procedures, could

lead to actuator malfunction and possibly void the warranty. For storage procedures exceeding one

year, consult Emerson Process Management for further recommendations.

As shipped from the factory, the ECAT system is an inherently weatherproof unit, providing that all

compartment covers and cable entry plugs remain intact. The actuator should be immediately stored

in a clean, dry warehouse, free from vibration and rapid temperature changes, until it can be installed

and energized.

If the actuator must be stored outside, store it off the ground at an elevation sufcient to prevent it

from being immersed in water or buried in snow. Check for any unpainted or exposed metal surfaces

and make sure they are protected with a coating of grease to prevent any corrosion. Cover the system

to prevent damage from site debris.

2.1.2 Tools and Materials Required

To complete these procedures, you will need the following documentation for the ECAT Actuator and

items indicated in the table below:

• General Arrangement Drawing

• Bill of Material

• ECAT System Schematic

• System Wiring Diagram

Table 2. Tools and Material Requirements

Tools and Material Requirements

Primary Power Source for the ECAT

(check the ECAT System Electrical Diagram for requirements)

Supplemental quantity of hydraulic uid, if needed

(See Section 2.7, Hydraulic Fluid and ECAT specication, for required uid type)

Hand Tools: complete complement of open end (SAE and metric) wrenches, screw drivers Philips

and at blade and a set of hex wrenches

Chains and lifting straps that are inspected and certied for the weight of the ECAT system

(check shipping weights)

Sealant for all cable and conduit entries (approvable by the National Electric Code or your country

standard and applicable local codes)

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

April 2021

Section 2: Installation

Installation

2.2 Valve Preparation

2.2.1 Remove Valve Gearing if equipped.

2.2.2 If valve is equipped with stops, remove valve stem extension housing. Examine the valve

stops to ensure no foreign material is present that would restrict normal travel of the valve.

Some valves are equipped with inspection ports in the valve housing for ease in examining

the stops.

2.2.3 Check alignment of stem key slot to the position of the valve. Normally with the valve in the

open position, the key slot is in line with the run of the pipeline. With the valve in the closed

position, the key slot should be 90° to the run of the valve.

2.2.4 The ECAT Actuator may be mounted to the valve at any time regardless of whether the valve

is under pressure.

2.3 Actuator Preparation

2.3.1 Once the ECAT Actuator is uncrated and cleaned for installation, check to ensure there will

be no interference with piping or other structure when the actuator is properly mounted to

the valve.

2.3.2 Check that all mounting materials such as fasteners, adapters, brackets etc. are on hand and

ready for use.

2.3.3 Check the actuator and valve to see that they are in the same relative position, that is either

open or closed. If the actuator must be moved, use the Handpump provided.

2.3.4 It is critical that the accumulator is charged with natural gas pipeline pressure prior to

operating the equipment. Refer to Section 2.8 for charging instructions.

NOTE:

Failure to charge the accumulator may cause the accumulator to not function properly.

April 2021

Installation, Operation and Maintenance Manual

VA-DC-000-1952 Rev. 0

Section 2: Installation

Installation

2.4 Lifting the ECAT System

NOTE:

All ECAT Considerations

When handling any ECAT actuator, be aware of tubing, accessories, handpump, accumulators, and

control enclosures. Straps and chains can become entangled and cause damage to these components.

NOTE:

Do not use hydraulic tubing and electrical cable for lifting.

! CAUTION

Be sure to use appropriately rated crane / hoist and straps / chains to raise and lower the actuator.

2.4.1 Shafer Rotary Vane Actuator Lifting

Use the integrated lifting eyes only to lift and move the ECAT system.

Figure 1 ECAT System Mounted on the Shafer Rotary Vane Actuator

Lift at these lift points only

Table of contents

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