HP- / IP- TURBINE BYPASS CONTROL VALVES

OPERATING and MAINTENANCE MANUAL

(Mechanical)

Plant Hai Phong 2 Thermal Power Plant

PRC

Owner Dongfang Electric Corporation

Purchaser

Supplied by CCI AG, Switzerland

Date 20.01.2009

Order No. S.O. 103794 / 103838 P.O. 201335 / 201341

Record copy: 6378

Das Urheberrecht an diesem Buch verbleibt bei CCI AG

The Copyright of this book remains with CCI Ltd
e-Mail: [email protected]

CCI AG • Im Link 11 • P. O. Box ·65 •·CH–8404 Winterthur • Switzerland

Telefon / Phone: 0041 52 264 95 00
 CONTENTS

Register 1: Revisions & Notes for the User

Register 2: Erection Instructions

Register 3: Description Main Components

Register 4: Electrical & Electro hydraulic Equipment

Register 5: General Maintenance Instructions

Register 6: Dismantling & Assembly: Steam- Control and Isolation Valves

HP Steam control valve HBSE 280 - 250 201335-1CH

LP Steam control valve NBSE 60 - 400 - 2 201335-4CH
LP Steam isolation valve NA 60 - 600 201335-5CH

- Dismantling & Assembly

Register 7: Dismantling & Assembly: Spray-water Control and Isolation Valves

Register 7.1: HP Spray - water control valve DRA® 100DSV 5 x 5 201305-2CH

- Installation, Operation and Maintenance Manual

Register 7.2: HP Spray - water isolation valve DRAG® 840G 5 x 5 201335-3CH

LP Spray - water control valve DRAG® 840H 5 x 5 201335-6CH
LP Spray - water isolation valve DRAG® 840G 5 x 5 201335-7CH

- Installation, Operation and Maintenance Manual

Register 8: Hydraulic Power Unit HV 200 ASHF-H

Register 9: Diagrams, Datasheets & Dimensional Drawings

Register 10 Sectional Drawings & Parts Lists

Register 11 Electronic Equipment

Register 12 Empty

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 REGISTER 1
REVISIONS & NOTES FOR THE USER
HEALTH AND SAFETY
Contents

REVISIONS 2

NOTES FOR THE USER 3

1 CONTENTS OF MANUAL 3
2 MODIFICATION SERVICE 3
3 ORDERING OF SPARE PARTS 3
4 GENERAL NOTES 3

HEALTH AND SAFETY 5

1 GENERAL SAFETY 5
2 WARRANTY 5
3 SITE HEALTH AND SAFETY INSTRUCTIONS 5
4 FIRE-RESISTANT FLUID FOR HYDRAULIC POWER UNITS
(TRIXYLENYL PHOSPHATE - 100 % NATURE PHOSPHATE ESTER) 6

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 REVISIONS
Date Reg. OBSOLETE NEW Remarks
to be removed to be inserted
06.01.2009 Final issue

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 NOTES FOR THE USER

1 Contents of manual
This manual contains the necessary documents and directions pertaining to all components
specified
in our scope of delivery. It pursues three objectives:
- description of plant components
- operating instructions
- maintenance instructions

2 Modification service
Justified modifications and additions which may become necessary, will be integrated
in our documents and sent to the client for exchange in his manual.

3 Ordering of spare parts

There is an ordering form for spare parts. Please use this form for your orders. By ordering spare
parts the following information’s are required:
ƒ Book number
ƒ Register & page
ƒ Item & name of the part

If provided, please also indicate the number of the corresponding drawing.

4 General Notes
Only correspondingly trained and instructed professional personnel is permitted to perform
operation and maintenance work at the CCI AG components. This manual does not contain
instructions and references that are part of the professional engineer's training and knowledge.
The same also applies to safety regulations while working with electrical systems. All applicable
regulations of local authorities as well as those of the plant owner must be followed. Especially
the ones concerning accident prevention must be strictly fulfilled. In case of serious
discrepancies with instructions given in this manual, please contact CCI AG.
CCI AG declines any responsibility concerning function and safety of supplied components and
systems, providing that:
- operating and maintenance instructions are not followed
- spare parts used were not supplied by or no written approval was given by CCI AG
- modifications made on components or systems, adding or removal of parts on CCI AG
components, or components and systems used beyond their range of application, without
prior written approval by CCI AG
- flow conditions exceeding the design conditions

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 From the content of this manual no claims can be evaluated, exceeding the contractual
obligations by CCI AG relevant to the customer. Only the contract between CCI AG and the
customer is relevant for guaranty and reliability issues.
CCI AG reserves the right, without notice, to alter or improve the designs or specifications of
the products described herein.
Our Service department is prepared to discuss solutions to any problems concerning the
maintenance and inspection procedures applicable to CCI AG equipment. Please direct all
inquiries to:

CCI AG Phone: (+41) 052 264 95 00

Im Link 11 Email: [email protected]
Industriepark Oberwinterthur WEB SITE: ccivalve.com
P. O. Box
CH – 8404 Winterthur, SWITZERLAND

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 HEALTH AND SAFETY

1 General Safety
This section contains general safety information, which must be observed during the installation
commissioning, operation and maintenance of the equipment.
Service engineers and operators must familiarise themselves with this information before
starting any maintenance or operating activity.
The manual should always be available for reference adjacent to the installed equipment.

2 Warranty
When damage caused by non-operating with these instructions causes may void the warranty!
For consequential losses over the CCI AG assume no liability!
When property or personal injury caused by improper handling or failure to observe safety
instructions created, the CCI AG assumes no liability!
In such cases expires each warranty claim

3 Site Health and Safety Instructions

Before performing any of the actions detailed within this manual, the “Site Health and Safety
Instructions” shall be read and fully understood.
Whenever the equipment is operated, maintained or used in any way, the procedures detailed
within the Health and Safety Dossier of the manufactures and any procedures detailed within
these instructions shell be followed.

3.1. Safety Labels and Notes

Special safety instructions, which apply to specific procedures or operations, are indicated in
manuals produced by CCI AG through the use of the following symbols:

Danger Sign with Note:

- Warning of the presence of dangerous electrical supplies
During electrical operation certain parts inevitably carry lethal voltages.
To avoid personal injury and damage to the process system, disconnect
the equipment from all electric power lines.

Warning Sign with Note:

- Failure to comply with these instructions could result in injury to personnel or damage to the
equipment.
The valve must be depressurised, cooled down
to room temperature and drained.

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 Observing sign with Note:
- Failure to comply with these instructions will be avoided the impact damage.
All repair and maintenance works on actuators must only
be carried out by qualified and trained personnel.

Care or notice sign with statement:

- Failure to comply with these instructions can avoid unnecessary delays.
Caution: Hydraulic fluid may escape!

In addition, notes and comments on coverage.

4 Fire-Resistant Fluid for Hydraulic Power Units

(Trixylenyl Phosphate - 100 % nature Phosphate Ester)
- For the detailed handling and safety information,
see the safety data sheet the manufacturer.

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 REGISTER 2
ERECTION INSTRUCTIONS
Contents

IMPORTANT NOTES ON THE INSTALLATION

OF CCI/ SULZER HIGH PRESSURE BYPASS VALVES 3
1 VALVE ARRANGEMENT 3
2 INLET LINE (BETWEEN BRANCH-OFF FROM THE LIVE STEAM PIPE AND THE HP-BYPASS VALVE
INLET) 3
3 OUTLET PIPE (BETWEEN HP-BYPASS VALVE AND THE BRANCH-OFF INTO COLD REHEATER LINE) 5
4 MEASURING THE STEAM TEMPERATURE DOWNSTREAM OF THE BYPASS VALVE 6
5 SPRAY WATER SYSTEM, LAYOUT OF SPRAY VALVES 6
6 PREFERRED ARRANGEMENT OF AN HP-BYPASS TO COLD REHEATER 6
7 ACCESSIBILITY OF VALVES, DISMANTLING 8
8 LAYOUT OF OIL SUPPLY UNITS 8
9 INSULATION 8
10 NOTES 9

IMPORTANT NOTES ON THE INSTALLATION

OF CCI/ SULZER LOW PRESSURE BYPASS VALVES 10
1 VALVE ARRANGEMENT 10
2 INLET LINE (BETWEEN BRANCH-OFF FROM THE LIVE STEAM PIPE AND THE LP-BYPASS VALVE
INLET) 10
3 OUTLET LINE 12
4 FORCES AND TORQUES ACTING ON BYPASS VALVES 12
5 ACCESSIBILITY OF VALVES, DISMANTLING 13
6 LAYOUT OF HYDRAULIC SYSTEM 13
7 MEASURES FOR NOISE REDUCTION 13
8 INSULATION 14
9 NOTES 14

GENERAL INSTRUCTIONS CONCERNING INSTALLATION

OF CCI AG/ SULZER VALVES 15
1 TRANSPORTATION AT INSTALLATION SITE 15
2 INSTALLATION 15
3 WELDING 16
4 HEAT-TREATMENT 16
5 CLEANLINESS 16

STORAGE INSTRUCTIONS FOR CCI AG/ SULZER VALVES AND SYSTEMS 17

1 CCI AG/ SULZER PACKING 17
2 PERMISSIBLE CONDITIONS FOR TRANSPORT AND STORAGE 17
3 STORAGE AREA CATEGORIES 17
4 SPECIAL STORAGE INSTRUCTIONS 17
5 TRANSFER OF RISK AND TAKE-OVER 18
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UNPACKING INSTRUCTIONS FOR CONTROL AND INSTRUMENTATION EQUIPMENT 19

RESISTANCE OF CCI AG/ SULZER VALVES AGAINST CHEMICAL CLEANING 20

INSPECTION OF THE VALVES AFTER BOILER BLOWOUT

WITH OR WITHOUT PRIOR CHEMICAL CLEANING 20

STEAM BLOWING OF CCI VALVES FOR HBSE 280 - 250 VALVES 21

RECOMMENDATIONS FOR PICKLING OF HYDRAULIC PIPES 23

FIGURES CONTENTS REGISTER 2 24

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 IMPORTANT NOTES ON THE INSTALLATION
OF CCI/ SULZER HIGH PRESSURE BYPASS VALVES

1 Valve arrangement
For easy maintenance the valves should preferably be installed with the actuator above the
valve.
Basically, other arrangements are possible, but CCI AG should first be consulted.

2 Inlet Line
(Between branch-off from the live steam pipe and the HP-Bypass valve inlet)
To ensure adequate continuous heating of the high pressure bypass valves, they are best installed
at a distance of 1.5 - 2 m from the live-steam piping. With this length of inlet pipe (main steam
pipe to valve inlet), optimal preheating of approx. 100° C below live steam temperature is
achieved. Insufficient preheating temperatures lead to excessive thermo cycling of the inlet
portion of the valve body. If the above described configuration is not possible, a separate pre-
heating line to the valve inlet must be provided (see below).
Since HP-Bypass valves are tight-seating, no additional isolation valve is needed upstream. If an
isolation valve is nevertheless fitted, e.g. for maintenance purposes, it must be ensured that the
HP-Bypass valve is kept at the correct preheating temperature for operational readiness (for
operational readiness, the isolation valve must be fully opened). With HP-Bypass valves with
safety function (e.g. all TRD 421) upstream isolation valves are not allowed.
The inlet line must be run so that condensate can flow back into the live-steam pipe, thus
avoiding thermal shocks due to the formation of condensate. Pipe sections which might give rise
to water pockets, must be avoided. If this is impossible such pipe sections must be equipped
with constantly-acting draining facilities of adequate capacity and pressure difference.
With a view to avoiding noise and vibration, it is advisable to provide a straight length of piping,
5 to 10 times the internal diameter long, immediately upstream of the valve.

Pre-warming
In order to avoid undesirable thermal shock for the HP-bypass valve, the valve should be
permanently pre-warmed to a temperature of 100 oC below live steam temperature. Adequate
pre-warming is ensured by installing the HP-bypass valve above the main steam pipe and at a
distance from the main steam pipe equal to 5-7 x DI (inner diameter of the inlet pipe). If this
arrangement is not possible, a separate pre-warming line connected to the valve inlet nozzle
must be provided.

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 Fig. 2-1 : Pre-warming

If the layout involves several bypass valves branching off from a common pipe, measures must
be taken to eliminate undesirable pressure oscillations in the inlet lines resulting from resonance.

Examples of poor layout: (LS = Live steam pipe)

Fig. 2-2 : Examples of poor layout

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 Examples of good layout

Fig. 2-3 : Examples of good layout

3 Outlet Pipe (Between HP-Bypass valve and the branch-off into cold reheater line)
In case the HP bypass system has to assume the function of a safety valve, (i.e. the system must
not be closed on loss of spray water), the outlet line must be checked to ensure that it can
withstand the maximum valve outlet temperature for a limited time (e.g. 10,000 hours, l%
creep).
Rising outlet lines downstream of the valve must be avoided. With rising lines there is a danger
of water pockets forming, either due to condensate collecting or to erroneous operation of the
water spray valves. Heavy, and possibly harmful, water hammer may be the result when the HP-
Bypass valve trips open. If rising lines are unavoidable, they must be fitted with reliable
constantly-acting draining devices. We recommend that two drains are fitted, namely a small
one for accumulations of condensate and possible water valve leaks, and a larger one which is
integrated in the start-up sequence (for further details see Section 5, Spray Water System).
Isolating valves on outlet lines are unacceptable because the outlets of HP-Bypass valve bodies
are designed for considerably lower pressures than the inlets.
Between valve outlet and the first downstream bend, a straight piece of pipe, length at least 5
times the inner diameter, should be provided. The steam velocity in the outlet pipe connection
must not exceed 100 m/sec at all specified operating conditions. It is possible to limit the steam
velocity to the aforementioned value by increasing the outlet pressure with a multi-hole orifice
close to the reheat pipe.
The outlet pipe should not be used for attaching fixed points. If however, this is unavoidable, the
fixed points should be arranged so that there is no transmission of noise to the steel structure or
to parts of the building. In the case of several parallel HP-Bypass valves, the outlet pipes must
be run separately to their end points (e.g. cold reheater pipe). If this is impossible, the following
notes should be observed:
- two pipes must never be joined in a T-junction so that the flows oppose each other
(i.e. at an angle of 180°)
- the pipes between valve outlets and junction points must be of different lengths.
- This helps to avoid causing acoustic resonances.

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4 Measuring the Steam Temperature Downstream of the Bypass Valve
The temperature measuring point ought to be as far away from the bypass valve as possible, the
minimum distance being 4 m. The measuring point must not be too close to the junction of
outlet line and cold reheater pipe, as it must be guaranteed that, when the bypass valve is closed,
the temperature at the measuring point is lower than the temperature in the cold reheat pipe (set
value).
Care must be taken to arrange the temperature measuring points so that they do not come into
contact with water (either condensate or water collecting in elbows downstream of a valve, or
non-evaporated, centrifugally separated water).

5 Spray Water System, Layout of Spray Valves

The spray water must be taken upstream of the boiler non-return valve. Water of optimal
temperature is obtained at the outlet of the feed water pump.
Standard arrangement of the valves:
- Control valve actuator positioned below the valve
- Isolating valve actuator positioned above the valve
With this arrangement it will be possible to weld the isolating valve outlet directly to the control
valve inlet. Other arrangements are possible but they are disadvantageous when carrying out
maintenance work. If arrangements other than standard are chosen, CCI AG should be consulted
as early as possible.
If isolating and control valves are installed with a pipe length between them, this pipe must be
designed for the same pressure as the line upstream of the isolation valve.
To obtain a compact valve arrangement, the spray water control valve should be placed as near
as possible to the connecting flange of the HP-Bypass valve. This reduces the volume of the
spray water pipe downstream of the control valve and improves controllability (lower dead time
between spraywater valve opening and steam cooling).

6 Preferred arrangement of an HP-Bypass to cold reheater

During normal operation (HP bypass closed), the spray water pipe may cool down to ambient
temperature. As soon as the HP bypass opens, cold spray water enters the bypass valve causing
local thermal shock. In order to minimize this effect as far as possible, the following measures
should be taken:
- keep the spray water pipe hot by means of adequate recirculation up to the spray water
isolation valve
- keep the length of the piping between the spray water isolation valve and the HP bypass
valve as short as possible (compact arrangement); this requires an automatic isolation valve
to be fitted upstream of each spray water control valve.
- Forces and Moments acting on the Bypass Valves

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 Arrangement of the ARS & DRE valves in a HP bypass to the cold Reheater

Fig. 2-4 : Arrangement of the ARS & DRE valves

Arrangement of the HBSE valves in a HP bypass to the cold Reheater

Fig. 2-5 : Arrangement of the HBSE valves

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 The valves must be arranged in the piping so that they have unimpeded mobility. Under no
circumstances must they constitute fixed points. From the valve manufacturer’s viewpoint, a
piping system is correctly designed if the valve housing is stiffer than the pipes connected to it,
i.e. the section modulus at all cross-sections of the valve must be higher than that of the weld
end (either inlet or outlet weld ends) with the lower section modulus. This is a design rule for
CCI valves. With this, the valve body can transmit forces and moments without suffering
distortion and there will be no undue effects which might impair the operability of the valve.
When checking the section module, possible differences of the materials of valve body and
pipes must be considered. The admissible section modules are found on the valve dimensional
sketches.

7 Accessibility of Valves, Dismantling

Bypass valves must be arranged so that there is sufficient space left for dismantling their internal
parts and for fitting the reconditioning tools for the valve seats. The required space is shown on
the dimensional sketches. CCI AG also recommends providing lifting gear above the valves,
such as I-girders with traveling cranes or hooks for block and tackle.
In order to enable manual operation of the control units on the actuators and supervision of the
glands during operation, unimpeded accessibility should be guaranteed. Where necessary,
platforms should be provided.

8 Layout of Oil Supply Units

There is no restriction in installing the Hydraulic Power Unit. It can be installed below, above or
at the same level as the valve. Our delivery includes fixings, hoses, cocks, filters and screwed
connections, in accordance with the hydraulic diagram. For additional information, see our
documents covering erection and commissioning of the hydraulic power system (see Register 7).

9 Insulation
A valve intended for hot service must have its valve body
and bonnet thoroughly insulated before initial use.

Proper insulation of the valve body and bonnet will

a) Protect the actuator and its accessories from damage due to excessive heat.
b) Assist in keeping the valve body adequately warm when the valve is closet.
At least 4" (100mm) of high efficiency thermal insulation should be applied to all exterior
surfaces of the valve body and bonnet. The whole valve must be insulated, including the bonnet
surface facing the actuator. This bonnet cover shall be designed for easy removal, to facilitate
the valve maintenance.

Insulation should not be applied to the actuator yoke legs. The actuator
yoke legs must be kept open to the air for efficient heat removal.

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 Example of insulation of a valve type

DRE-ASM.tif

Fig. 2-6 : Example of insulation of a valve type DRE

10 Notes
We recommend that you send us your preliminary layout drawings prior to finalisation. We shall
be glad to examine them on the basis of our experience, and, if deemed necessary, offer further
recommendations.
If the HP bypass valves are to take over the function of safety valves, the code requirements
concerning erection must be observed (e.g. Germany: TRD 421, Para. 6). In this case, it should
further be noted that the parts of the installation mentioned below must be designed for short-
term safety operation without spray water (loss of either the spray water supply or the water
spray valve).

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 IMPORTANT NOTES ON THE INSTALLATION
OF CCI/ SULZER LOW PRESSURE BYPASS VALVES

1 Valve arrangement
We recommend installing the valves in the vertical position, i.e. with the actuator above the
valve . This is the most convenient position for maintenance work. Basically, other
arrangements are possible, but CCI AG should first be consulted.

2 Inlet Line
(Between branch-off from the live steam pipe and the LP-Bypass valve inlet)
The inlet line must be run so that condensate can flow back into the live-steam pipe, thus
avoiding thermal shocks due to the formation of condensate.
Water pockets must be avoided. If this is impossible, such pipe sections must be equipped with
constantly acting draining facilities of adequate capacity and pressure difference.
With a view to avoiding noise and vibration, it is advisable to provide a straight section of
piping, 5 to 10 times the internal diameter long, immediately upstream of the valve.
S-bends with two elbows in different planes should be avoided near the inlet of the valve.
If the layout involves a number of bypass valves branching from a common pipe, measures must
be taken to eliminate undesirable pressure oscillations in the inlet lines resulting from resonance
(see Example 1 to 5).
The valves must be pre-heated to a temperature of approx. 50°C (max. 100°C) below live steam
temperature, i.e. if the distance between valve and HRH (hot reheater)-line exceeds approx. 2m
a separate pre-warming line to the valve inlet is required.
The bypass valves ensure good tightness. Therefore, no additional upstream isolating valve is
needed.
If an isolating valve is nonetheless fitted, it must be ensured that the bypass valve is held at the
correct pre-warmed temperature to keep it at operating readiness.

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 Examples of poor layout: (LS = Live steam pipe)

Fig. 2-7 : Exampel of poor layout

Examples of good layout:

Fig. 2-8 : Examples of good layout

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3 Outlet Line
Outlet lines that rise downstream of the valve must be avoided. With rising lines there is a
danger of water pockets forming due to condensate collecting. When the bypass valve trips
open, heavy water hammer may occur and cause damage.
If rising lines are unavoidable, they must be fitted with open drains. In case an open drain is not
possible, reliable constantly-acting drain devices must be provided, a small one for
accumulations of condensate, a large one that is integrated into the start-up procedures.
If there are two or more parallel bypass valves, each outlet line must have its own drain
facilities.
GOOD POOR

Bypass
outlet pipe

Drain
Fig. 2-9 : Bypass outlet pipe Good and Poor

If two or more bypass valves are arranged in parallel, their outlet pipes should be led separately
to their end points. If this is not possible, in no case must two pipes be joined in a T-junction so
that the flows oppose each other (i.e. at an angle of 180°) and the pipes between valve outlet and
junction point must be of different lengths. These measures help to avoid causing acoustic
resonances.
Fixed points on the valve outlet piping should be avoided or designed in a way that prevents
noise transmission from the piping to the steel structure.
- Between the valve outlet and the first bend downstream, a straight pipe section of
length min. 5 I.D. should be provided.
- Steam velocity at the valve outlet branches should never exceed 250 m/sec.
- If necessary, the velocity must be limited by fitting one or more multi-hole orifices
in the outlet line.

4 Forces and Torques acting on Bypass Valves

Valves must be freely hung in the pipe work. Under no circumstances may they form fixed
points. From the valve manufacturer's viewpoint, a piping system is properly designed if the
valve body is more rigid than the piping connected to it, i.e. the section modulus of the valve
nozzles must be greater than that of the connected piping. If this condition is fulfilled, the valve
body can transmit forces and moments without becoming deformed and there are no
unacceptable effects which might impair the operability of the valve.
When checking section modulus figures, allowance must be made for any differences in the
materials of valve nozzles and the piping.
The admissible section modulus figures are shown on the dimensional sketches.

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 If for any reason the piping has higher section modulus figures than the valve nozzles, we must
be informed of the forces and moments that occur. We will then check the valve body on the
basis of these figures. If the results are unacceptable, the piping system will have to be made
more flexible.

5 Accessibility of Valves, Dismantling

For the bypass valves, we recommend that sufficient space above and around the valve are
provided for
- dismantling
- short term storage of valve internals
- using tools for any refreshing work on the valve seat
The space requirement for removing the stem and for using special maintenance tools
(seat cutting tool, seat grinding tool) is shown on the dimensional sketches.
Furthermore, we recommend providing lifting gear, e.g. an "I" girder with travelling crane, or
hooks for block and tackle above the valve. If the valves are installed in a non-vertical position,
lifting must be done with particular care.
Good accessibility to the servovalves and blocking elements of the actuators and to the valve
stuffing boxes during operation must be provided to permit manual operation of the former and
inspection of the latter. Where necessary, platforms must be provided.

6 Layout of Hydraulic System

No static pressure is permitted in the leakage line between servovalve and hydraulic power unit,
which could exert pressure on the servovalve.
Therefore, the leakage pipe must not be run above the servovalve.
Our delivery includes hoses, cocks, filters and screwed connections, in accordance with the
hydraulic diagram.
Piping and fixings materials are not included in the scope of supply.
For additional information, see our documents covering erection and commissioning of the
hydraulic power system.

7 Measures for noise reduction

When noise reduction measures are planned, it should be considered that in most applications
the bypass is a start-up/shut-down device with relatively short operating periods. Most
regulations accept higher noise levels for short operation periods. The number of expected start-
ups/shut-downs should also be considered.
If the steam velocity in the outlet nozzle is lower than 200 m/sec., we recommend the following
arrangement:
Fit a straight, thick-walled pipe section with a length of at least 5 x I.D. (but min. 2 m),
immediately downstream of the valve, the internal diameter coinciding as closely as possible
with the valve outlet nozzle internal diameter as shown in the dimensional sketch. If an elbow
follows this straight pipe section, we recommend flaring the line downstream of the straight
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 section to provide a conical transition section and fitting an elbow with enlarged diameter to
reduce steam velocity. If reasons of space make the foregoing solution impossible, the straight
pipe section should nonetheless be retained followed by the elbow with the same internal
diameter as the pipe, but with a conical section leading to a larger diameter then being fitted
downstream of the elbow (see Example 7 to 9).
If the velocity is higher than 200 m/sec. then a multi-hole orifice should be installed to limit the
velocity in the outlet nozzle to 150-200 m/sec.
A further improvement is possible by replacing the thermal insulation on the outlet piping by
combined thermal/noise insulation.
- min. 100 mm mineral fiber (80-100 kg/m3), e.g. pressed shells
- an outer shell of 1 mm steel plate
Noise bridges between piping and outer shell must be avoided.
The solution shown in Example 7 is better than that in Example 8; but Example 8 is better than
that in Example 9.
Example 7 Example 8 Example 9

Fig. 2-10 : Noise bridges between piping and outer shell

8 Insulation
Refer to the Paragraph 8. and Figure 2.5 in the instruction:" “INSTALLATION OF HIGH
PRESSURE BYPASS VALVES”.

9 Notes
We recommend that you send us your preliminary layout drawings prior to finalizing the design.
We shall be happy to examine them in the light of our experience and make any
recommendations which may seem necessary.

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 GENERAL INSTRUCTIONS CONCERNING INSTALLATION
OF CCI AG/ SULZER VALVES

1 Transportation at Installation Site

The valves shall be transported from the storage place to the place of installation using utmost
care. In order to avoid any damage, they shall, whenever possible, not be unpacked until shortly
before they are fitted.
Serious injuries may occur if valves and components are not handled
properly. Therefore, suitable lifting equipment must be properly used
and attached, i. e. carefully wrap rope slings around valve yoke or
actuator, or use the lifting points provided

All applicable codes, regulations and industrial practices for handling loads must be followed.
These include, but are not limited to, the following precautions:
a) Rope slings shall be free of kinks and twists
b) Position lifting hook above the load such that the load does not swing when lifting
c) Care shall be taken that the load is well secured and balanced
d) The operator shall ensure that rope slings are not handled on the hoist hook without his
knowledge
e) Carrying loads above people is not permitted

2 Installation
The valves are delivered with the stem in the closed position, and they shall be welded-in in this
condition. While welding the valve into the piping, pay close attention to the flow direction as
marked by an arrow on the valve body.
- When fitting the valves, it is imperative that they are welded into the piping free of stress.
The protection plugs on the valve nozzles shall not be removed until just before fitting and
the machined surfaces of the welding joints shall not be damaged. The valve shall only be
lifted using the lifting points provided.
If no such lifting points are provided, the valve shall under no circumstances be lifted by
attaching any of its valve trim to the lifting device. Only the valve body may be attached to the
lifting device. Under no circumstances it is permitted to attach additional fix points for the
piping system, for additional loads, or for tack welding, to the valves.
The valves and actuators must be accessible for maintenance work.

Use care when lifting and handling loads to ensure that accessories and
lines as well as sealing surfaces of valves and flanges are not damaged.

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E02_103794-103838.doc
3 Welding

3.1. Welding the valve in piping lines

The instructions concerning welding and heat-treatment shall be furnished by the supplier of the
piping, or by the company carrying out the welding. These instructions must observe for
welding the valves into the piping. The valve shall be welded-in with the stem in the "closed"
position.

Do not use valve stems or piston rods of actuators for grounding

(earthing) during welding operations.

3.2. Welding the spray water nozzles

Before welding of the valves into the piping the water connection
spray nozzles follow the below -listed instructions:

If the distance from the pipe welding end to the spray nozzles is less than 300 mm, the nozzles
have to be removed for the welding and post weld heat treatment so that the heat treatment does
not affect the spring strength.
If the distance is more than 300 mm and the nozzles are not removed, then using insulation you
have to make sure that the maximum allowable temperature at the spray nozzle housing
of 250°C is not exceeded during the post weld heat treatment.

4 Heat-treatment
If heat-treatment of welds is required, care must be taken during the annealing process that the
valve is not subjected to any inadmissibly high temperatures (maximum to the annealing
temperature as indicated in annealing instruction for the material used). The valve body shall not
be insulated (heat transfer). The internal parts of the valve must not be removed during the
annealing process.

5 Cleanliness
Absolute cleanliness must be observed throughout the installation operation. Actuator and valve
assembly shall be covered to prevent dirt, emery dust or other foreign matter from getting into
the valve and actuator. In the event of long periods of time between fitting and commissioning
(without preservation of the installation), it is recommended that all parts are treated with an
anti-corrosive agent.
In the case of hydraulic actuators, make sure that the drillings for the hydraulic fluid are always
completely closed. Where provided, the control units, solenoid valves and safety devices shall
not be fitted until just before commissioning of the installation.

730/05.08 Gf Register 2-16

E02_103794-103838.doc
 STORAGE INSTRUCTIONS
FOR CCI AG/ SULZER VALVES AND SYSTEMS

The equipment supplied should be stored in clean and dry conditions, and be protected against
mechanical damage, and kept in the CCI AG/ Sulzer original packing in closed rooms.

1 CCI AG/ Sulzer Packing

With a few exceptions, all items of the equipment are packed in wooden boxes for
transportation. Sensitive parts are additionally sealed into plastic bags. The boxes can be
manipulated with cranes and lifters. If the country of destination requires seaworthy packing, the
boxes are lined with jute-reinforced tar paper. For more details, refer to CCI AG/ Sulzer's
detailed packing specification. The client should specify if dust-free packing, packing for long-
time storage, etc. is required.
When the boxes arrive on site, they must be checked for possible damage that has occurred
during transportation. If unpacking of the material is necessary for inspection, it must be
repacked in the original way, whereby plastic sheets must be re-sealed and silica bags replaced.

2 Permissible Conditions for Transport and Storage

When not indicated otherwise, the following transport and storage conditions are acceptable:
- Transport and storage temperature -25 ... + 70°C
- Mean annual relative humidity of air (DIN 400 40) 75% at 35°C
- Exposure to dew must be avoided.
- The safest protection against dew is the storage of the equipment in dry rooms.
- Special storage instructions apply for storage near the sea (up to 100 km distance from the
coast).

3 Storage Area Categories

The storage areas must be protected against fire. Smoke can be harmful to the goods. The
storage areas should be accessible to authorized personnel only.
A closed room is understood as being a room that completely protects the stored material against
any weather effects, exposure to sunlight and against dirt and dust. The material must not be
subjected to extreme humidity or dew. Roofs and walls made of plastic or tarpaulin are not
accepted as closed rooms.

4 Special Storage Instructions

4.1. Valves
If a storage period is longer than 6 months, the CCI AG/ Sulzer can supply the valve gland
packings separately at the client's request. In such cases the valves should be checked before
installation.

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4.2. Actuators
Electric actuators must be completely filled with oil as soon as it is certain that they will be
stored for more than one year.
- The vent filters must be replaced by locking screws.
- Hydraulic actuators and the associated oil supply equipment must be checked by an expert
authorized by CCI AG/ Sulzer after one year of storage.

4.3. Measuring Transformers and Electronic Equipment

The packing guarantees protection against corrosion for six months. If a longer storage period is
anticipated, the original packing must on no account be opened upon receipt. Therefore, all
important data are written on the outside of the packing cases. If storage exceeds one year, the
measuring transformers are to be checked prior to erection by personnel authorized by CCI AG/
Sulzer. The control system electronic modules can be stored in the unopened original packing
for 2 years without checking.

4.4. Spare parts

Special inspection intervals for spare parts must be agreed upon between Purchaser and CCI
AG/ Sulzer.

5 Transfer of Risk and Take-over

The Purchaser bears all risks of the goods in accordance with the Contract, i.e. CIF, FOB, etc. as
defined under INCOTERMS. If dispatch is delayed or prevented by circumstances beyond CCI
AG/ Sulzer's control, the goods will be stored in the CCI AG/ Sulzer Works at the Purchaser's
expense and risk.
If the goods are stored on site the client bears all risks. He shall also bear the costs for any
damage, theft or destruction caused by events beyond CCI AG/ Sulzer's control such as water,
fire, etc. It is up to the Purchaser to take out insurance against damage of any kind. Even if
insurance cover is arranged by CCI AG/ Sulzer, it shall be taken out on behalf of the Purchaser
and at his expense and risk.

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E02_103794-103838.doc
 UNPACKING INSTRUCTIONS
FOR CONTROL AND INSTRUMENTATION EQUIPMENT

Equipment for control and instrumentation is generally high-technology material which on no

account shall be exposed to normal weather conditions (see storage instructions). Moisture,
especially in the vicinity of the sea, and dust can result in irreparable damage.
For the most part, the equipment is vacuum-packed with desiccants. We strongly recommend
that the equipment be left in its original transparent vacuum packing, unopened, until installation
work is started. If this package is opened for any reason, the equipment must then be re-packed
in a new vacuum pack, and new desiccant must be used. A written record must be made of the
opening and re-packing operations.
All plug-in electronic modules are removed from the control cubicle for transportation and
delivered in special polystyrene shipping cases. A package is supplied for each chassis frame
occupied in the cubicle. Inside these shipping cases the electronic modules are arranged
according to their layout in the chassis frame.
The electronic modules must only be inserted in the cubicles,
i.e. in the chassis frames, by the commissioning engineer after
an assembly test has been carried out

The electronic modules belonging to each cubicle are vacuum-packed in the polystyrene
shipping case. Each individual cubicle is also vacuum-packed. The cubicle and the electronic
modules are packed and shipped together in one crate.
When assembly work is started, the electronics room must be dust-free, dry and lockable. The
crates are then opened, the electronic modules in their original package are stored in a suitable
store, and the side walls of the crate are removed in the electronics room so that the cubicle can
easily be erected with the help of the jack rings supplied. All 4 jack rings must be used to ensure
that the cubicle does not tilt.
Damage to the packages or visible shipping damage to the cubicles or equipment must be
reported immediately in writing.

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E02_103794-103838.doc
 RESISTANCE OF CCI AG/ SULZER VALVES
AGAINST CHEMICAL CLEANING

Usually pickling-proof materials are used for the valves. Yet it must be noted that the 13%
chrome steels are pickle-proof only to some degree when certain pickling methods are used.
For this reason the materials used must be submitted to the pickling company for judgement.
The necessary information is contained in sectional drawings and relevant material lists.
The pickling company decides whether the materials used are pickling-proof.
After pickling the gland packing must always be replaced. Since they soak up pickling liquid
they might later cause corrosion on the valve stem.

INSPECTION OF THE VALVES AFTER BOILER BLOWOUT

WITH OR WITHOUT PRIOR CHEMICAL CLEANING

Inspection with prior chemical cleaning

If the boiler has been chemically cleaned, then the pressure seals and gland packings of the
affected valves must be replaced, in order to prevent corrosion due to residual amounts of acid
left in the packings.

Blowout
During the boiler blowout, particles of dirt in the blowout steam can cause damage to valve seats
and stems. Therefore special internals should be used for blowout.
Furthermore, the inside of the valve body is to be cleaned to remove any foreign particles.

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E02_103794-103838.doc
 STEAM BLOWING OF CCI VALVES
FOR HBSE 280 - 250 VALVES
Fig.: HBSE 280-… Drawing 103.231.040.500 Design 200

Dismantling and Assembling Instruction

1. Dismantle valve according to Instruction Manual. Be sure, that the outlet cage remains in
the valve body, if provided.
2. Install blow-out protection device into valve body according to the corresponding drawing.
Use existing packing rings during blow out process, providing gasket was not damaged
during dismantling.

If new packing rings are required they must be compressed in according

to the follow paragraphs:
3. Attach the new lower packing ring with care to the seat protection disc and slide them into
the valve body groove. Make sure the disc is fully seated and has metal-to-metal contact
with bottom of valve body recess.
4. Insert carefully the inlet cage. Make sure that the cage is fully seated in the annular groove
between the seat disc and valve body and the packing ring is properly fitted.
Never rotate the inlet cage while resting on the lower packing ring.
Otherwise the packing ring will be damaged!

5. Attach a new upper packing ring to the flange and slide them into the valve body. Be sure
that the packing ring is properly fitted.
Never rotate the flange while resting on the upper packing ring.
Otherwise the packing ring will be damaged!

6. Using lifting gear, lower carefully the dummy bonnet over the flange and fit it to the valve
body.
7. Restore the bolted or nuts connection between the dummy bonnet and the valve body
according to the “GENERAL MAINTENANCE INSTRUCTIONS.
8. Use the bolt or nut tightening data from the corresponding Top assembly drawing.
9. Check that the dummy bonnet has metal-to-metal contact with the valve body. If not, re-
tighten the lower packing ring until contact is achieved. Re-check the metal-to-metal
contact between the pressure seal plug and valve body.
10. Carry out blow-out process.
11. Loosen and remove the bolts or nuts connection and dismantle blow-out protection device
in reverse order.
12. Assembly valve according to Instruction Manual. Replace packing rings by new ones!

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E02_103794-103838.doc
 Fig.: HBSE 280 - …

All not positioned Parts are in the plant

Fig. 2-11 : Blow out device

Item # Name of the part Item # Name of the part

001 Seat protection disc 034 Packing ring Ø 205/ 188 x 18
002 Inlet cage 035 Packing ring Ø 200 / 180 x 18
003 Flange
004 Dummy Bonnet SW Width across flat
Mt Torque

730/05.08 Gf Register 2-22

E02_103794-103838.doc
 RECOMMENDATIONS FOR PICKLING OF HYDRAULIC PIPES

If pipes are bent in hot condition then they have to be pickled in sections afterwards. It is
advantageous to dismantle the pipes for pickling and, if possible, to have it done by a company
specialized in pickling.
If the pipes are installed in such a way that they cannot be taken apart, the work must be carried
out on site. This, however, requires considerably more material and time.

To prevent renewed contamination, erection should be

carried out immediately after pickling.

Pickling is not required if:

- pipes used have been correctly preserved
- cleanliness has been strictly observed
- in case of welding, pipe inner bores have been continuously flushed with pressurized inert
gas
Pickling is a chemical method of cleaning and is carried out using saponifying
alkalis, organic solvents and acids. Special agents (inhibitors) are used to delay
the corrosive effect of the acids without impairing the cleaning capability.

In order to protect the materials against uncontrolled acid corrosion, certain flow velocities of
pickling medium must be maintained. Therefore, pickling is limited to the pipes only. But in any
case, the hydraulic fluid tank, valves and hoses must either be dismantled or bypassed. The
subsequent flushing, however, is intended to clean the entire system, i.e. also the tank and hoses.

Flushing Instructions
See corresponding document: "Commissioning of Hydraulic Power Unit HV and Piping".

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E02_103794-103838.doc
 FIGURES CONTENTS REGISTER 2
FIG. 2-1 : PRE-WARMING 4
FIG. 2-2 : EXAMPLES OF POOR LAYOUT 4
FIG. 2-3 : EXAMPLES OF GOOD LAYOUT 5
FIG. 2-4 : ARRANGEMENT OF THE ARS & DRE VALVES 7
FIG. 2-5 : ARRANGEMENT OF THE HBSE VALVES 7
FIG. 2-6 : EXAMPLE OF INSULATION OF A VALVE TYPE DRE 9
FIG. 2-7 : EXAMPEL OF POOR LAYOUT 11
FIG. 2-8 : EXAMPLES OF GOOD LAYOUT 11
FIG. 2-9 : BYPASS OUTLET PIPE GOOD AND POOR 12
FIG. 2-10 : NOISE BRIDGES BETWEEN PIPING AND OUTER SHELL 14
FIG. 2-11 : BLOW OUT DEVICE 22

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E02_103794-103838.doc
 REGISTER 3
DESCRIPTION OF MAIN CONTROL COMPONENTS
Contents

ELECTROHYDRAULIC ACTUATOR SYSTEM WITH PROPORTIONAL VALVE 3

1 PURPOSE 3
2 DESIGN AND OPERATION 3
3 ELECTRO HYDRAULIC ACTUATOR SYSTEM (OPEN/ CLOSE CONTROL) APL 9
4 ELECTRO HYDRAULIC ACTUATOR SYSTEM (OPEN/ CLOSE CONTROL) APLE OR 4/3WEDZ 10
5 ELECTRO HYDRAULIC ACTUATOR SYSTEM (CONTROL WITH PROPORTIONAL VALVE) 11

ACTUATORS ASM AND GHZ CLASS 12

1 PURPOSE 12
2 DESIGN AND OPERATION 12
3 ACTUATOR TYPES (ASM OR ASMF AND GHZ OR GHZF) 12

CONTROL UNIT 4/3WEDz 14

1 PURPOSE 14
2 DESIGN AND OPERATION 14

PV CONTROL UNITS 16

1 GENERAL SYSTEM DESCRIPTION 16

2 BLOCKING FUNCTION 16
3 POSITIONING FUNCTION 16
4 MEASURING CONNECTIONS 16
5 ERECTION AND COMMISSIONING 16
6 REPAIRS 17

SAFETY CONTROL SYSTEM SSB 18

1 PURPOSE 18
2 DESIGN AND OPERATION 19

FEEDBACK TRANSMITTER 22

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POSITION TRANSMITTER SG 15A/15B 23

1 APPLICATION 23
2 FUNCTION 23
3 TECHNICAL DATA 24
4 APPLICATION NOTE 25

FIGURES CONTENTS REGISTER 3 26

TABLE CONTENTS REGISTER 3 26

720/10.05 AV Register 3-2

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 ELECTROHYDRAULIC ACTUATOR SYSTEM WITH PROPORTIONAL VALVE
Description

1 Purpose
The CCI AG electro-hydraulic actuator system is used in connection with control valves, safety
valves, etc. The electro-hydraulic actuator combines high positioning forces with a fast
positioning speed and a high positioning accuracy.
In combined safety/ bypass stations the additional cost of the safety control system is minimal.
Furthermore, it is possible to have stored actuating power with hydraulic fluid accumulators
which are available even when a power failure occurs.
If the plant already has a central hydraulic power supply unit, the CCI AG hydraulic actuating
systems can be added at a reasonable cost.

2 Design and operation

2.1. Summary
The electro-hydraulic actuating system is designed as a modular system. It consists of the
following components, as shown in Fig. 3-1:
Actuator ASM or GHZ required in every case
Hydraulic power unit only if there is not already a hydraulic power unit
Control unit PV
Positioning unit PVR
Stepping control unit APL or4/3We
} PV and APL or 4/3WEDz is required
in every case

Safety control system SSB as required

Safety bypass system SBE as required

Fig. 3-1 :Electro hydraulic

actuating system

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 Each actuator requires either a control unit or a stepping control unit. In addition, up to three
additional control units per valve can be fitted as required (Fig. 3-2).

Fig. 3-2 : Actuators with control units

2.2. Actuator ASM or GHZ

The actuators are double-acting hydraulic cylinders. The actuator piston rod is moved by the
controlled supply and discharge of hydraulic fluid from either side of the piston. In this manner,
positioning forces of up to 1200 kN are achieved with high positioning speeds and wide stroke
ranges.
Features of ASM-type actuators are the wear-free bearings of their moving parts and their
outstanding sealing. Up to four control units can be mounted directly onto each actuator and
each control unit can have a different function. In cases where increased system reliability is
required, control units with the same function are installed.
Also GHZ-type actuators have wear-free barings on their moving parts and their outstanding
sealing. Up to two control units can be mounted directly onto each actuator and each control unit
can have a different function.

2.3. Hydraulic power unit

The hydraulic power unit supplies the hydraulic energy necessary for the actuators. A single unit
can supply several actuators. The main component of the hydraulic power unit is the pump
which pumps the hydraulic fluid from a tank into a hydraulic accumulator. The unit also has
control and safety equipment to guarantee the supply of hydraulic fluid from the accumulator.
The purpose of the accumulator is to cover load peaks. A pressure-reducing valve keeps the
system pressure constant within narrow limits.

720/10.05 AV Register 3-4

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 The hydraulic accumulators are delivered for safety reasons for transport
without nitrogen charging pressure.
Before start-up all hydraulic accumulators in the system have to be filled with
nitrogen on the nominal charging pressure.
The nominal charging pressure is to be taken from the hydraulic data sheet in
the appropriate register.

Fig. 3-3 : Hydraulic power unit

2.4. Control unit PV

The control unit converts the electrical signals from the control system into a flow of hydraulic
fluid.
It controls the intake and discharge of hydraulic fluid to and from the piston chambers of the
actuator in a continuous control mode, thus permitting very precise positioning of the actuator.
With high response sensitivity and stability, stroking times of less than three seconds can be
achieved without difficulty.
The blocking function ensures that the actuator is held drift-free in its position during manual
mode or if a malfunction occurs.
- Furthermore, the blocking function is assured by two pilot-controlled check valves. If power
failure or loss of hydraulic pressure occurs, the check valves close the bores to the actuator.
- The control unit solenoid is excited by a current signal which is proportional to the deviation
of the set value from the actual value. With a higher current on the solenoids, the flow
through the directional valve increases.

Fig. 3-4 : Control unit PV

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2.5. Stepping control unit APL / APLE and 4/3WEDz
The stepping control unit is the simplest way of controlling an actuator. It provides only a step-
control mode and is used for pure on/off operation.
The central part of the stepping control units is a 4/3-way valve operated by two solenoids. A
system of throttling orifices and releasable check valves makes it possible to set the positioning
speed independently in either direction and ensures that the actuator is held in its position
without drifting.

Fig. 3-5 : Stepping control unit APL, APLE and 4/3WEDz

2.6. Open-Close control unit 4/2WEDz

The control unit is the simplest way of controlling an actuator. It provides only a step-control
mode and is used for pure on/off operation.
The central part of the stepping control units is a 4/2-way valve operated by one solenoid.

Fig. 3-6 : Open / Close unit 4/2WEDz

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2.7. Safety control system SSB
The safety control system ensures that even if the central power supply fails, the actuator can be
reliably positioned in a pre-determined end position if required. The energy necessary for this is
taken from an additional hydraulic accumulator with a storage capacity sufficient for one or
more strokes, depending on the requirements.
The heart of the system is the safety control system, which is mounted directly on the actuator
either as a single version or as a multiple-redundant version. It consists essentially of two
releasable check valves, which, under normal operation, keep the pressure line from the
accumulator to the actuator and the return line to the tank closed. When in use, a solenoid-
operated 3/2-way valve opens the check valves. The additional hydraulic accumulator, which is
not used during normal operation, is kept fully charged by the central hydraulic supply unit. It is
installed in the immediate vicinity of the actuator and connected to the system with a special
connecting block, which can be equipped with a monitoring pressure gauge or pressure switch.

Fig. 3-7 : Safety control system SSB

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2.8. Safety bypass system SBE
The safety bypass system allows the valve to open without any external energy source. Only the
forces exerted by the medium (usually steam) on the valve stem are utilized. This system is used
primarily in connection with HP bypass stations and with actuator operated safety valves of the
MSV or HSV type.

Fig. 3-8 : Safety bypass system SBE

The safety bypass system is nearly always arranged redundantly to increase system reliability.
Three identical safety bypass blocks are mounted directly onto the actuator. Each consists of a
pilot valve and a main valve. If the solenoid pilot valve is de-energized, the system
automatically opens a bypass line between the upper and lower piston chambers of the actuator.
As a result, the valve stem is moved to its open position by the force exerted on the valve stem
by the medium.

720/10.05 AV Register 3-8

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3 Electro hydraulic Actuator System (Open/ Close Control) APL

1 Hydraulic power unit 5 Position transmitter

2 Stepping control unit APL 6 Position controller
3 Actuator 7 Connection for additional actuators
4 Control valve

P Pressure line T Return line

Fig. 3-9 : Electro hydraulic Actuator System (Open/ Close Control)

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4 Electro hydraulic Actuator System (Open/ Close Control) APLE or 4/3WEDz

1 Hydraulic power unit 5 Position transmitter

2 Stepping control unit APLE or 4/3We 6 Position controller
3 Actuator 7 Connection for additional actuators
4 Control valve

P Pressure line T Return line

Fig. 3-10 : Electro hydraulic Actuator System (Open/ Close Control)

720/10.05 AV Register 3-10

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5 Electro hydraulic Actuator System (Control with Proportional Valve)

1 Hydraulic power unit 5 Position transmitter

2 Proportional valve (incl. blocking function) 6 Position controller
3 Actuator 7 Connection for additional actuators
4 Control valve

P Pressure line T Return line

Fig. 3-11 : Electro hydraulic Actuator System (Control with Proportional Valve)

720/10.05 AV Register 3-11

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 ACTUATORS ASM AND GHZ CLASS
Description

1 Purpose
Actuators are part of the CCI AG electro-hydraulic actuating system. Together with the "yoke"
that constitutes the mechanical connection to the valve, they form the valve drive.
ASM and GHZ actuators are manufactured in a variety of sizes and designs. They can provide
actuating forces of up to 1200 kN at high actuating speeds over wide stroke ranges.

2 Design and operation

ASM actuators are double-acting hydraulic cylinders. They feature highly effective internal and
external sealing and wear-free bearing arrangements of their moving parts.
The actuator piston rod is operated by the controlled supply and discharge of hydraulic fluid to
and from the upper and lower actuator piston chambers. See figure 3-9.
The coupling, which is easily accessible through the large openings in the yoke, transfers the
actuating force from the actuator spindle to the valve stem. A mechanical position indicator is
provided on a stroke scale. Refer to the Figure 3-9.
In addition to a position transmitter (R-SG), up to four control units can be mounted directly on
the actuator; these can have different functions, or the same functions for enhanced system
safety.
Depending on the application, ASM actuators are also available with opposing piston rod for
equal acting areas and integral spring. The actuator stroke can be limited using spacer rings.

3 Actuator types (ASM or ASMF and GHZ or GHZF)

Depending on the type of hydraulic fluid, mineral oil or fire resistant fluid/phosphate ester fluid
(e.g. “Fyrquel”) to be used in operation, there are different types of actuator. For operation with
mineral oil types ASM / GHZ are used and types ASMF / GHZF are used for fire resistant
fluids/phosphate ester fluids.
Actuators operated with fire resistant fluids/phosphate ester fluids must be equipped with special
seals (e.g. Viton or FPM O-rings). The design of the piston rod guide is another difference
between the two actuator types.

720/10.05 AV Register 3-12

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 Fig. 3-12 : Actuators with control units

720/10.05 AV Register 3-13

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 CONTROL UNIT 4/3WEDz
Description

1 Purpose
The Control unit 4/3WEDz is used to operate actuator with reduced control exactness and is
often used for pure On/Off operation. It is designed for stepping control mode.
The operating speeds for the two directions of operation of the valve can be set individually. In
its passive, i.e. de-energised state, the Control unit holds the actuator drift-free in the set
position.

2 Design and operation

The central part of the Control units 4/3WEDz is a 4/3-way valve (001) which is operated by
two solenoids (002). This valve controls the actuator directly without further hydraulic
amplification.
When de-energised the valve is in its central position with: all connections (P, T, A and B) are
closed. As soon as one of the two electromagnets is activated, the valve connects the pressure
pipe (P) and the return pipe (T) with or for other piston slide of the control drive.
In each of the two connection lines between the 4/3-way valve and the actuator there is a
throttling/check valve (004).
The positioning time for each of the two directions of actuator travel can be set individually with
the two throttling check valves. Throttling is always applied to the return flow. The actuator can
also be controlled manually using the two manual control knobs (H). The arrows in the
following Figure indicate the direction of motion of the valve when the relevant manual control
knob is operated.
With the help of the two manual control knobs (H) can be the actuator controlled manually.
The arrows indicate the direction of motion of the valve during operation of the manual control
concerned.

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 ASM / GHZ Actuator 001 4/3-way valve
H Manual control knob 002 Solenoid
P Pressure line 004 Throttle/check valve
T Return line to tank 020 Connection block
Fig. 3-13 : Stepping control unit 4/3 WEDz

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 PV CONTROL UNITS
Description

1 General System Description

The control unit serves for the positioning of the cylinder. With the blocking system the
cylinder, if necessary, can be held over longer time in a position.

2 Blocking Function
The blocking function is done by two releasable check valves and one 3/2-way valve. By
energising the 3/2-way valve, the two check valves are opened hydraulically and permit oil to
flow freely to and from the cylinder through the A and B connections. When the 3/2-way valve
is de-energised, the check valves close and the actuator is blocked in its momentary position.
The 3/2-way valve has an emergency spring-centered manual operation feature, which allows
manual operation during a power failure.

3 Positioning Function
The positioning function is done using a proportional 4/3-way valve. This valve converts an
electric signal into a proportional hydraulic signal. This valve is a pure positioning element and
is only able to function with the corresponding amplifying and controlling electronics.
Parameter adjustments of this valve are only possible electronically. The proportional valve has
spring-centered emergency manual operation which allows manual switching if a power failure
occurs.

4 Measuring Connections
Measuring connections are installed in the hydraulic lines A and B to the upper and lower
cylinder chambers, which allow pressure measurements to be made during operation.

5 Erection and Commissioning

Hydraulic valves are functional units which are precision manufactured. If the necessary
cleanliness is observed during erection, commissioning and operation, these hydraulic valves
ensure perfect function. Because of the mechanical demands and ageing, the hydraulic fluid
must be checked for quality and purity at regular intervals.
The installed filters must be replaced or cleaned in accordance with the instructions. When
replenishing or replacing hydraulic fluids, it should be noted that the hydraulic fluid as delivered
is usually not directly suitable for use in a hydraulic system, because of the solid particle
content. The necessary cleanliness of the fluid can not be guaranteed due to the, often very long,
transportation channels from manufacturer to user. The new hydraulic fluid, either being
replenished or replaced, must therefore be added through the filter on the power unit. With
regard to the fineness of the filling filter, it must be at least as fine as the filter used in operation
in the plant. It is better to use an even finer filter.

720/10.05 AV Register 3-16

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 The actuator cylinder connecting surfaces for the control unit must be absolutely clean to ensure
complete sealing of the O-ring. On the control units, the cover plates are to be removed from the
connections. Prior to mounting make sure that the O-rings are correctly positioned in their
grooves. The block can now be bolted firmly to the cylinder, whereby the bolts must be
tightened, alternating diagonally, with the specified torque.
So that the complete hydraulic system now functions as expected, the system must be
thoroughly vented. Thereby it attains the necessary rigidity to provide the required position
accuracy.

6 Repairs
Plant operators are advised not to attempt any repair work, other than replacing seals and gaskets
on the control components.
A repair by the plant operator one should advise against, if this is to go beyond a seal exchange
at the elements.
This is not to be understood in such a way that our devices would be so sensitively, trouble-
prone or complicated that these work cannot be settled by a mechanic. Rather it is important that
the hydraulic elements are tested and measured the test stand, so that a perfect function can be
guaranteed after repair by the manufacturer.
We generally recommend with plant repairs the exchange of the complete components.

30 Check valve
40 3/2-way solenoid valve
50 Proportional solenoid valve

Fig. 3-14 : PV Control Units

720/10.05 AV Register 3-17

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 SAFETY CONTROL SYSTEM SSB
Description

The SSB safety control systems are produced in the follow versions:
- with safety control unit SSB6 for the actuator type ASM63
- with safety control unit SSB10 or SSB10z for low flow rates
- with safety control unit SSB16 for middle flow rates
- with safety control unit SSB32 for high flow rates

1 Purpose
The safety control system SSB, which comprises the safety control unit (SSB), the accumulators
manifold (SB) and the stand-by accumulator (ZS), is part of the CCI AG electro hydraulic
actuating system.

It is used
- to position a valve in the open or closed (predetermined) position in the event that the central
hydraulic power supply fails
- for fast stroking of a valve into the open or closed position
It takes hydraulic fluid from a stand-by accumulator, the capacity of which is sufficient for one
or more full strokes of the valve, depending on requirements.
A single safety control system SSB can stroke a valve in only one direction. Two independent
control systems SSB are needed if stroking in both directions is required, although this is
possible with only one stand-by accumulator.

ASM Actuator
SSB Safety control unit
SB Accumulator manifold
ZS Stand-by accumulator

Fig. 3-15 : Safety control system SSB

720/10.05 AV Register 3-18

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 The SSB safety control unit can be mounted either to extend or retract
the piston rod. (Fig. “Safety control system SSB” shows retracting).
Arrows on the unit indicate the direction of flow.
Refer to the Figure “Arrow of SSB direction”.

2 Design and operation

2.1. The safety control unit

The safety control unit is mounted directly on the actuator and is completely independent of any
control devices that may be fitted. When the system is activated, the effect of all other control
devices is overridden.
In normal operation, i.e. when the safety control system is inactive, a releasable check valve
(010) isolates the actuator from the accumulator. A second releasable check valve (010) and a
check valve (RV) prevent the oil from being drained from the actuator. Switching the pilot valve
drips the SSB unit; the two releasable check valves are opened. The pressurised fluid from the
accumulator drives the actuator piston to the required end position.
The SSB unit is available as energise to trip or de-energise to trip.
The entire system is leakage-free, so that the accumulator retains its charge for a long time after
failure of the hydraulic power supply.
The flow rate, and with it the stroking speed, can be set with a flow-regulator or orifice (004),
the setting is protected from interference with a lead seal.
The SSB 32 is designed for high flow only, therefore no flow-regulator is needed and two
releasable check valves are in parallel.

2.2. Stand-by accumulator and accumulator manifold

The stand-by accumulator is delivered for safety reasons for transport
without nitrogen charging pressure.
Before commissioning all accumulators in the system have to be filled up
with nitrogen to the appropriate charging pressure.
The nominal value of the charging pressure is specified in the hydraulic
data sheet in the corresponding register.

The accumulator manifold (SB) connects the stand-by accumulator (ZS) and the safety control
unit (SSB) to the central hydraulic power supply. The check valve (RV) ensures that the
pressure in the accumulator is maintained. The pressure relief valve (022) protects the
accumulator from excessive pressure. In addition it allows discharge from the accumulator. The
accumulator manifold is equipped with a pressure gauge (017) and if needed can also be fitted
with an adjustable pressure switch (018).

720/10.05 AV Register 3-19

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 ASM Actuator 001 Pilot valve
RV Check valve 004 Flow-regulating cartridge or restrictor
SB Accumulator manifold 010 Releasable check valve
SSB Safety control unit 017 Pressure gauge
ZS Stand-by accumulator 018 Pressure switch (optional)
022 Pressure relief valve
Fig. 3-16 : Hydraulic diagram of the safety control system SSB 6, -10, 16

ASM Actuator 001 Pilot valve

RV Check valve 010 Releasable check valve
SB Accumulator manifold 017 Pressure gauge
SSB Safety control unit 022 Pressure relief valve
ZS Stand-by accumulator
Fig. 3-17 : Hydraulic diagram of safety control system SSB 32.1-2

720/10.05 AV Register 3-20

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 Fig. 3-18 : Arrows of SSB direction

720/10.05 AV Register 3-21

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 FEEDBACK TRANSMITTER

The Feedback Transmitter is produced in different versions for example:

- R-SG 15 + 4K Position transmitter and 4 limit switches
- R-4K only 4 limit switches
Feedback Transmitter R-SG 15 + 4K is for control valve. The Position transmitter SG 15
measures the valve position and transmits the position to the Position controller. The Position
controller compares the valve position with the demand position and moves the valve according
the deviation. The limit switches are not used for positioning but may be used for indicating
Valve positions.

Feedback Transmitter R-4K is for valve with open/close function.

Fig. 3-19 : Feedback Transmitter

720/10.05 AV Register 3-22

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 POSITION TRANSMITTER SG 15A/15B

1 Application
The SG 15 is a position transmitter with a capacitive position sensor whose solid and compact
design assures high resistance to climatic and mechanical influences and to electrical
interference. It is simple to install and adjust. The SG 15 position transmitter can be used
wherever a mechanical position is to be converted (by angle of rotation) into an analog electric
signal.
The SG 15A type can be used for rotation angle range of 0° to 30…70°; the SG 15B type for 0°
to 60…140°.

2 Function
The position transmitter consists essentially of two parts: the sensor element (a variable
capacitor) which detects the position, and the electronics which convert the rotary motion into
an electrical signal.
The entire electronics are accommodated in SMD technology on the disk-shaped laminated
PCB, which surrounds the capacitor. The transmitter is connected on the front plate by two
Fasten plugs.
- The position transmitter uses two-wire technology, i.e. only two conductors are needed for
both power supply and measuring signal. Regardless of the supply voltage applied, the
transmitter takes a current proportional to the position (4…20 mA or 5…15 mA).
The angular position is transmitted mechanically via the rotor of the butterfly capacitor (1). This
variable capacitor with two part capacitances working in opposite directions is thus the time-
determining element for the multivibrator (2). The frequency/voltage converter (3) forms the
arithmetical mean of the square-wave voltage, which is a measure of the angular position of the
variable capacitor. After this rectification, the voltage is converted into an impressed DC signal
in the amplifier (4). Since the potentiometers are accessible from the front plate the zero (Io) and
the end value (∆I) of the output signal can be adjusted. Using the drift compensation amplifier
(5), the temperature drift is compensated to minimise temperature influence. The voltage source
(6) supplies the entire electronics of the position transmitter. The input protection (7) safeguards
against reverse voltage and electromagnetic interference.
∆I
SG15
α 1 2 3 4 7
G
+

5 6

ϑ I0
URe -

Fig. 3-20 : Connection diagram

720/10.05 AV Register 3-23

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
3 Technical data
Tab. 3-1: Limit values:
Supply voltage Us 12...30 V
Superimposed AC voltage (Us = 15…27 V) ≤ 3 Veff
Current limitation ≤ 37 mA
Actuator stroking time ≥ 10 ms (0 to 100 %)
Limiting frequency (–3 dB) 250 Hz
Angle of rotation unrestricted rotation, no stop
Rel. rotation angle range 0° to 30°...70° (SG15A)
0° to 60°...140° (SG15B)
Axial and radial forces ≤ 20 N
Driving torque ≤ 0,1 Nm
Immunity to interference EN 50082-2, March 1995
ESD IEC 801-2 15 kV
Burst IEC 801-4 4 kV
Surge IEC 801-5 (1,2/50 µs / 2 Ω) ± 2 kV sym., ± 4 kV asym.
EMF IEC 801-3 (80 MHz...1 GHz) 10 V/m
EMF IEC 801-6 (150 kHz...80 MHz) 10 V EMF
Shock (IEC 68-2-27, DIN 40046E) 50 g/11 ms, 3-3 shocks in both
directions of the 3 axes
Vibration (IEC 68-2-6, DIN 40046F) 10 g, f ≤ 200 Hz, each of the 3 axes
Operating temperature –25...+100 °C
Admissible air humidity ≤ 95 % rLF @ 35 °C
Climate class (DIN 40040) HMC

Tab. 3-2: Nominal- values:

Supply voltage 24 V
Dynamic internal resistance > 1 MΩ
Zero current I0 4 mA or 5 mA
Current rise ∆I 16 mA or 10 mA
Linearity ≤ ±0,5 % FSR
Stability, relative to the full rotation angle of 70° ≤ ±1,0 % FSR
or 140°, as the case may be: –25…+80°C
Dimensions See dimensional drawing
Weight 0,3 kg

720/10.05 AV Register 3-24

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
4 Application note
The position transmitter cable should be twisted and single-shielded. The cable screen should be
connected with the feedback transmitter chassis (RSG) according to drawing 4-103.195.658

Dimension and Characteristic

∅ 68 SG 15A - Characteristic

I [mA]
Io=min.
∆I=max.
∅6 20

4
r.z.
∠α
0° 90° 180° 270° 360°
4x ∅ 4,5 lin. range
∅ 90

∅ 80 SG 15B - Characteristic
52
I [mA]

10 Io=min.
∆I=max.
2
9,5

10
4
r.z. ∠α
0° 90° 180° 270° 360°
∅ 70 lin. range

Fig. 3-21 : Dimension and Characteristic

Ordering information
- SG 15A Art. Nr. 103.195.480.200
- SG 15B Art. Nr. 103.195.495.200

Adjustment instruction
In order to operate the position transmitter in the linear range, the relative zero must be found
before adjusting. The valve actuator must be moved to its minimum position. Set I0 to minimum
(ccw), ∆I to maximum (cw). Set the variable capacitor to minimum (ccw) with rising curve, (or
to cw with falling curve), then turn cw (or ccw with falling curve) until current I rises abruptly.
Correct ccw (or cw with falling curve) to achieve
the minimum current I again. The relative zero (r.z.) thus found is shown in the diagrams. Then
adjust current I to 4 mA (5 mA) with potentiometer I0. Move the valve actuator into maximum
position and adjust current I to 20 mA (15 mA) with potentiometer ∆I.

720/10.05 AV Register 3-25

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 FIGURES CONTENTS REGISTER 3

FIG. 3-1 : ELECTRO HYDRAULIC ACTUATING SYSTEM 3

FIG. 3-2 : ACTUATORS WITH CONTROL UNITS 4
FIG. 3-3 : HYDRAULIC POWER UNIT 5
FIG. 3-4 : CONTROL UNIT PV 5
FIG. 3-5 : STEPPING CONTROL UNIT APL, APLE AND 4/3WEDZ 6
FIG. 3-6 : OPEN / CLOSE UNIT 4/2WEDZ 6
FIG. 3-7 : SAFETY CONTROL SYSTEM SSB 7
FIG. 3-8 : SAFETY BYPASS SYSTEM SBE 8
FIG. 3-9 : ELECTRO HYDRAULIC ACTUATOR SYSTEM (OPEN/ CLOSE CONTROL) 9
FIG. 3-10 : ELECTRO HYDRAULIC ACTUATOR SYSTEM (OPEN/ CLOSE CONTROL) 10
FIG. 3-11 : ELECTRO HYDRAULIC ACTUATOR SYSTEM (CONTROL WITH PROPORTIONAL VALVE) 11
FIG. 3-12 : ACTUATORS WITH CONTROL UNITS 13
FIG. 3-13 : STEPPING CONTROL UNIT 4/3 WEDZ 15
FIG. 3-14 : PV CONTROL UNITS 17
FIG. 3-15 : SAFETY CONTROL SYSTEM SSB 18
FIG. 3-16 : HYDRAULIC DIAGRAM OF THE SAFETY CONTROL SYSTEM SSB 6, -10, 16 20
FIG. 3-17 : HYDRAULIC DIAGRAM OF SAFETY CONTROL SYSTEM SSB 32.1-2 20
FIG. 3-18 : ARROWS OF SSB DIRECTION 21
FIG. 3-19 : FEEDBACK TRANSMITTER 22
FIG. 3-20 : CONNECTION DIAGRAM 23
FIG. 3-21 : DIMENSION AND CHARACTERISTIC 25

TABLE CONTENTS REGISTER 3

TAB. 3-1: LIMIT VALUES: 24
TAB. 3-2: NOMINAL- VALUES: 24

720/10.05 AV Register 3-26

Rev. 1: 730/08.07 Gf
E03_103794-103838.doc
 REGISTER 4
ELECTRICAL & ELECTRO-HYDRAULIC COMPONENTS
Contents

STEPPING CONTROL UNIT 4/3WEDZ 2

CONTROL UNIT PV 4 3

CONTROL UNIT PV 6 4

CONTROL UNIT PV 6K 5

SAFETY CONTROL UNIT SSB 10Z 6

POSITION TRANSMITTER R-SG15+4K 7

POSITION TRANSMITTER R-4K 8

FIGURES CONTENTS REGISTER 4 9

Corresponding Function description, Connection and Wiring

Diagrams see register “Electronic Equipment”

730/02.08 Gf Register 4-1

E04_103794-103838.doc
 STEPPING CONTROL UNIT 4/3WEDZ

Item # Part name Item # Part name

001 1 4/3-way valve 009 2 O-rings Ø 17,17 x 1.78
004 1 Double throttle check valve 015 3 Screws M 4 x 65, SW 3
006 4 O-rings Ø 4.5 x 1.5 020 1 Distributor manifold
008 4 O-rings Ø 4.5 x 1.5
100 1 Stepping control unit complete, 4/3WEDz
290 1 Seal set, consisting of items: 006, 008 and 009 (these items are not available
separately)

Fig. 4-1 : Stepping control unit 4/3WEDz

730/02.08 Gf Register 4-2

E04_103794-103838.doc
 CONTROL UNIT PV 4

Item # Part name Item # Part name

10 1 Distributor plate NG4 60 3 Screws M 5 x 45
20 2 Screw coupling to mini-measuring 70 3 Screws M 5 x 40
device 1620 / M 14 x 1.5 ED
30 2 Check valve 90 4 Screws M 6 x 60
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG4, W 130 2 Connections for P & T
290 1 Seal set, consisting of items 30, 40, 50, 110 (these items are not available
separately)

Fig. 4-2 : Control Unit PV 4

730/02.08 Gf Register 4-3

E04_103794-103838.doc
 CONTROL UNIT PV 6

Item # Part name Item # Part name

10 1 Distributor plate NG6 60 3 Screws M 5 x 45
20 2 Screw coupling to mini-measuring 70 4 Screws M 5 x 50
device 1620 / M 14 x 1.5 ED
30 2 Check valve 90 4 Screws M 8 x 60
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG6, 130 2 Connections for P & T
290 1 Seal set, consisting of items 30, 40, 50, 110 (these items are not available
separately)

Fig. 4-3 : Control Unit PV 6

730/02.08 Gf Register 4-4

E04_103794-103838.doc
 CONTROL UNIT PV 6K

Item # Part name Item # Part name

10 1 Distributor plate NG6 60 3 Screws M 5 x 45
20 2 Screw coupling to mini-measuring 70 4 Screws M 5 x 50
device 1620 / M 14 x 1.5 ED
30 2 Check valve 90 4 Screws M 6 x 60
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG6, 130 2 Connections for P & T
290 1 Seal set, consisting of items 30, 40, 50, 110 (these items are not available
separately)

Fig. 4-4 : Control Unit PV 6K

730/02.08 Gf Register 4-5

E04_103794-103838.doc
 SAFETY CONTROL UNIT SSB 10Z

Item # Part name Item # Part name

001 1 3/2-Way solenoid valve 013 2 Packing rings Ø 30.15/ 24.55 x 3.05
004 1 Non Return Throttle Cartridge 014 2 O-rings Ø 18.72 x 2.62
005 1 O-ring Ø 17.17 x 1.78 015 2 Back-up rings Ø 24/ 19.6 x 1
008 4 Screws M 6 x 100, SW5 016 2 Back-up rings Ø 23/ 20.2 x 1
009 2 O-rings Ø 17.17 x 1.78 017 2 O-rings Ø 20.35 x 1.78
010 2 Pilot operated cartridge check 021 5 O-rings Ø 5.28 x 1.78
valves Ma = 140 Nm
011 2 O-rings Ø 17.17 x 1.78 027 3 Screws M 5 x 45
012 2 O-rings Ø 31.47 x 1.78
100 1 Safety control unit complete, SSB 10z
290 1 Seal set, consisting of items: 005, 009, 011 to 017, 021(these items are not available
separately).

Fig. 4-5 : Safety control unit SSB 10z

730/02.08 Gf Register 4-6

E04_103794-103838.doc
 POSITION TRANSMITTER R-SG15+4K

Item # Part name Item # Part name

001 1 Shaft seal 004 4 Position microswitches
002 2 Grooved ball bearing 005 1 Position transmitter SG15A
003 1 O-ring Ø 110.49 x 5.33 006 1 Damping element complete
EH Adjusting lever
100 Position transmitter complete, R-SG15+4K

Fig. 4-6 : Position Transmitter R-SG15+4K

730/02.08 Gf Register 4-7

E04_103794-103838.doc
 POSITION TRANSMITTER R-4K

Item # Part name Item # Part name

001 1 Shaft seal 004 4 Position microswitches
002 2 Grooved ball bearing 006 1 Damping element complete
003 1 O-ring Ø 110.49 x 5.33
EH Adjusting lever
100 Position transmitter complete, R-4K

Fig. 4-7 : Position Transmitter R-4K

730/02.08 Gf Register 4-8

E04_103794-103838.doc
 FIGURES CONTENTS REGISTER 4

FIG. 4-1 : STEPPING CONTROL UNIT 4/3WEDZ 2

FIG. 4-2 : CONTROL UNIT PV 4 3
FIG. 4-3 : CONTROL UNIT PV 6 4
FIG. 4-4 : CONTROL UNIT PV 6K 5
FIG. 4-5 : SAFETY CONTROL UNIT SSB 10Z 6
FIG. 4-6 : POSITION TRANSMITTER R-SG15+4K 7
FIG. 4-7 : POSITION TRANSMITTER R-4K 8

730/02.08 Gf Register 4-9

E04_103794-103838.doc
 REGISTER 5
GENERAL MAINTENANCE INSTRUCTIONS
Contents

RECOMMENDATIONS ON REVISION INTERVALS

FOR CCI AG/ SULZER -CONTROL VALVES 3
1 CONTROL VALVES IN GENERAL 3
2 CONTROL VALVES WITH INTEGRATED INJECTION SYSTEM
IN THE HP AND LP-BYPASS SYSTEM 3
3 REPLACING WELDED-IN VALVE SEATS 4

CLEANING INSTRUCTIONS 5
1 CLEANING MATERIALS REQUIRED 5
2 CLEANING METHODS 5

INSTRUCTIONS FOR BOLT THREAD LUBRICATION AND TORQUE SETTINGS

FOR CCI AG/ SULZER VALVES 6
1 LUBRICANT 6
2 LUBRICATING THREADS 6
3 LOOSENING/TIGHTENING SCREWS ( BOLTS AND NUTS) WITH TORQUE WRENCHES, TORQUE
AMPLIFIERS OR SINGLE HEAD HYDRAULIC TORQUE DEVICES. 7
4 HYDRAULIC BOLT – PRE-STRESSING – DEVICE WITH CYLINDER PISTON HEADER. 9

HYDRAULIC ACTUATOR GHZ(F) 10

1 REMOVING THE COMPLETE ACTUATOR UNIT 11
2 ASSEMBLY OF THE COMPLETE ACTUATOR UNIT 11

STEPPING CONTROL UNIT, TYPE 4/3WEDZ3 13

1 REPLACING THE COMPLETE 4/3WEDZ STEPPING CONTROL UNIT 13
2 REPLACING INDIVIDUAL COMPONENTS 14
3 DISMANTLING THE REMOVED STEPPING CONTROL UNIT INTO ITS MAIN COMPONENTS 15
4 ADJUSTING THE POSITIONING TIMES 16

PV 4 CONTROL UNIT 17
1 REPLACING THE COMPLETE PV CONTROL UNIT 17
2 REPLACING INDIVIDUAL COMPONENTS 18

PV 6 CONTROL UNIT 19
1 REPLACING THE COMPLETE PV CONTROL UNIT 19
2 REPLACING INDIVIDUAL COMPONENTS 20

PV 6K CONTROL UNIT 21
1 REPLACING THE COMPLETE PV CONTROL UNIT 21
2 REPLACING INDIVIDUAL COMPONENTS 22

0342/11.01 HS Register 5-1

Rev. 4: 06.08 Gf
E05_103794-103838.doc
SAFETY CONTROL UNIT SSB 10Z 23
1 REPLACING THE COMPLETE SAFETY CONTROL UNIT 23
2 REPLACING INDIVIDUAL COMPONENTS 24

ZS STAND-BY ACCUMULATOR AND SB ACCUMULATOR MANIFOLD 27

1 WORK ON ZS STAND-BY ACCUMULATOR 27
2 WORK ON THE SB ACCUMULATOR MANIFOLD 31

ADJUSTMENT OF POSITION TRANSMITTER SG 15 A,

POSITION MICROSWITCHES AND POTENTIOMETER 32
1 GENERAL INFORMATION 32
2 ADJUSTMENT 33

INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER 35

WIRING DIAGRAM OF THE POSITION MICROSWITCHES

INSIDE POSITION TRANSMITTERS 36

SERVICE RECORDS 37

FIGURES CONTENTS REGISTER 5 38

TABLES CONTENTS REGISTER 5 38

0342/11.01 HS Register 5-2

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 RECOMMENDATIONS ON REVISION INTERVALS
FOR CCI AG/ SULZER -CONTROL VALVES

1 Control Valves in general

During the first two years of operation, CCI AG recommends overhauling control valves once
a year. Based on the experience and evaluations thus gained, the plant maintenance department
can determine the required inspection intervals for the control valves (e.g. a 2-year-cycle).
For overhauls it is mandatory that for every valve to be inspected at least one complete set of
sealing rings and gaskets must be available. We also recommend that the inspections and
overhaul work is recorded in standard control reports for statistical purposes (see the example
at the end of this register). This will be helpful in accurately judging the condition of the
valves during the following years of operation.
If the above-mentioned procedure for overhauls is not practicable, we recommend the
following:
During the first year of operation, overhaul one control valve of each type and application. In
the second year of operation, depending on the number of valves of the same type and
application installed, overhauls should be performed on two other control valves of each type.
This procedure should be continued until all control valves of each type and application have
been overhauled once.
The above applies only if no abnormal behaviour of the control valves occurs during normal
operation. Should this be the case, all the valves of the type concerned must be overhauled in
due course.

2 Control valves with integrated injection system in the HP and LP-Bypass system
Control valves with integrated injection are very high thermal and mechanical loads.
It concerns the valve types ARD or DRS and HBSE as well NBSE.
Therefore, it is important that the jet cage as well as the internal surface of the valve body and
downstream of the seat, are inspected for cracks at the following intervals:
- First inspection no later than one year after commissioning does, or after 100 start-up and
shut-down cycles, counted from the beginning of commissioning.

Further inspections:
- For plants with the operating, on base load or in a weekend-shut-down mode, are intervals
of maximum 2 years.
- For plants with frequent bypass operation (e.g. daily start-up), at least one valve should be
opened and inspected once a year.
- Depending on the condition of the inspected valve, it will be decided whether or not to
inspect other.
For valves used as controlled safety valves, the regulations of local authorities governing
periodic inspections must be observed.

0342/11.01 HS Register 5-3

Rev. 4: 06.08 Gf
E05_103794-103838.doc
3 Replacing welded-in valve seats
If it becomes necessary to replace valve seats, the welding shall be done according to the
corresponding specification. Requests for welding specifications should be addressed to:

CCI AG
Customer Service
Im Link 11
CH-8404 Winterthur, Switzerland

Note:
Exchange of the jammed valve seats is given in the „Dismantling
and Assembly Instructions“, of the corresponding valve.

0342/11.01 HS Register 5-4

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 CLEANING INSTRUCTIONS

1 Cleaning materials required

The following materials should be used to comply with CCI recommended cleaning methods.
Materials and methods may be changed to meet local conditions and requirements.
- crocus cloth, 400 grit
- cleaning cloths
- brush, S.S. wire
- brush, non-metallic
- solvent
- methyl alcohol, anhydrous purified
- ethyl alcohol, anhydrous denatured
- acetone, technical grade

Re-distilled solvents must be equivalent to new solvent

Solvents may be toxic and flammable. Refer to the manufacturer's

instructions before using. Eye protection is required when solvents or
compressed air is used

2 Cleaning methods
The following procedures should be used for cleaning CCI control valve and CCI pneumatic
actuator components.

Do not use abrasives to clean valve components

2.1. Immerse parts in solvent.

2.2. Remove stubborn accumulations of dirt from the sealing surfaces with a non-metallic brush.
2.3. Remove scale, rust, and minor pitting from the interior of the body using 400 grit crocus cloth
or a S.S. wire brush.
2.4. Rinse parts with clean solvent.
2.5. Direct compressed air through each disk passage, in the reverse direction of flow.
2.6. Dry parts with cleaning cloths and/or compressed air

0342/11.01 HS Register 5-5

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 INSTRUCTIONS FOR BOLT THREAD LUBRICATION
AND TORQUE SETTINGS FOR CCI AG/ SULZER VALVES
(Excluding actuators)

Inspections to be carried out before starting work:

- The valve must be depressurized, drained and allowed to cool to ambient temperature.
To ensure quick and easy dismantling during overhauls, all bolts, nuts and screws should be
handled with care and greased in accordance with the instructions below.

1 Lubricant
- Only BLASOLUBE 315 is to be used on all bolted connections on water and steam valves.
CCI AG rejects any responsibility if other lubricants are used.

2 Lubricating threads
- Inspect bolt and hole threads for impurities and damage, if necessary, re-cut the thread
holes.

Never trim the bolts threads!

2.1. Lubricate the threads of all the parts of the bolt connections.
2.2. Fasten the pressure seal plug, the bonnet or the cover, etc. provisionally with 2 or 4 bolts.
2.3. Screw the rest of the bolts by hand in without washers until the bolt heads are well seated.
2.4. If a bolt cannot be fully screwed in without exerting force, the threaded hole should be cleaned
and the thread inspected again.
2.5. Inspect the bolt thread too, and if damaged, use a new bolt.
2.6. Do not trim the bolt thread!
2.7. Unscrew and remove all the bolts again.
2.8. Lubricate the bolt threads thoroughly once again.
2.9. Apply lubricant to both sides of the washers.
2.10. Take the washers to the bolts and screws them in.
Bolted connections consisting of threaded bolts and the nuts must also to be treated as
described above.

0342/11.01 HS Register 5-6

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E05_103794-103838.doc
3 Loosening/Tightening screws ( bolts and nuts) with torque wrenches, torque amplifiers
or single head hydraulic torque devices.
The tightening torques in Nm are given in the valve parts list or top assembly drawing.
If a torque amplifier is used, care should be taken that the stop of the reaction bar for
compensating the reaction forces (torque) is placed as far away from the bolt as possible.
Tighten and loosen the screws (bolts and nuts) ever alternating diagonally in accordance to the
table “Example of bolt tightening sequence”.

Hydraulic torque wrench

Before start any work, read they the settled operating instruction of the supplier attentively.
Especially the ones concerning accident prevention must be strictly fulfilled.
Determine the hydraulic-pressure according the „Pressure- / torque – table from the
manufacturer
3.1. Loosening the screws (bolts and nuts).

The bolted connections are to be loosened in 2 stages:

3.1.1. Loosen all screws (bolts or nuts) alternating diagonally (see table “Example of bolt tightening
sequence”), to 50% of the specified torque.
3.1.2. Loosen and remove all screws (bolts or nuts) them alternating diagonally completely.
3.2. Tightening the screws (bolts and nuts).

The bolted connections are to be tightened in 5 stages:

3.2.1. Lubricating and installing of the bolt connection is described under paragraph 1.
3.2.2. Tighten all the bolts (or nuts) by hand, alternating diagonally (see table “Example of bolt
tightening sequence”).
3.2.3. Tighten all screws (or nuts), alternating diagonally to 25% of the specified torque.
Build up the oil pressure required for "25% of specified torque" (see mounting instructions)
counter checks the selected pressure at the pressure gauge.
3.2.4. Tighten all bolts (or nuts), alternating diagonally, to 50 % of the specified torque.
Build up the oil pressure required for "50% of specified torque" (see mounting instructions)
counter checks the selected pressure at the pressure gauge.
3.2.5. Tighten all bolts (or nuts), alternating diagonally, to 75% of specified torque.
Build up the oil pressure required for "75% of specified torque" (see mounting instructions)
counter checks the selected pressure at the pressure gauge.
3.2.6. Tighten all bolts (or nuts) to the full specified torque. Build up the oil pressure required for
"full specified torque" (see mounting instructions) counter checks the selected pressure at the
pressure gauge.
3.2.7. Repeat the complete cycle as necessary until all screws (or nuts) are tightened equally.

0342/11.01 HS Register 5-7

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E05_103794-103838.doc
 Fig. 5-1 : Example of bolt tightening sequence

- to tighten bolts in a diagonal sequence

- to tighten bolts crosswise

0342/11.01 HS Register 5-8

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E05_103794-103838.doc
4 Hydraulic bolt – pre-stressing – device with cylinder piston header.
- Before start any work, read they the settled operating instruction of the supplier attentively.
Especially the ones concerning accident prevention must be strictly fulfilled.
- A hydraulic bolt – pre-stressing – device consists of a hand lever pump or a pump unit,
4-cylinder piston header and a complete set of hydraulic hoses.
- Pre-stressing force FSO in KN.
- Determine the hydraulic-pressure according the „Pressure- / pre-stressing force FSO in
accordance with the pre-stressing diagram from manufacturer.
4.1. Loosening screws (or nuts).
4.1.1. Mount the 4 cylinder piston header evenly distributed around the circumference, onto the
screws (or nuts), see table “Example of bolt tightening sequence”.
4.1.2. Loosen the 4 screws (or nuts) to 50% of the specified pre-stressing force.
4.1.3. Remove the cylinder piston header from the screws (or nuts) and mount the hydraulic bolt –
pre-stressing – device onto the next 4 screws (or nuts).
4.1.4. Loosen and remove all screws (or nuts).
4.1.5. Dismantle the hydraulic bolt – pre-stressing – device.
4.2. Tightening screws (or nuts).
4.2.1. Lubricating and installing of the bolt connection is described under paragraph 1.
4.2.2. Mount the 4 cylinder piston header on the screws (or nuts) evenly distributed around the
circumference, onto the screws (or nuts), see table “Example of bolt tightening sequence”.

For safety reasons, the studs must protrude

over the nuts by at least 2 threads!

4.2.3. The necked-down bolts will be tensed with 50% of the force in accordance with in the diagram
identified force FSO and the nuts has to be until it seats solidly.
4.2.4. The necked-down bolts are again with 50% of FSO force retightened until the nuts can`t be
turned anymore!
4.2.5. Check the clearance „S“, whether the cover is parallel and in seat solidly .
4.2.6. The necked-down bolts will be tensed with 100% of the force FSO and the nuts has to be
brought in a seat solidly position..
4.2.7. Necked-down bolts once more with 100% of the force FSO tightened until the nuts can`t be
turned anymore!

0342/11.01 HS Register 5-9

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E05_103794-103838.doc
 HYDRAULIC ACTUATOR GHZ(F)
Maintenance Instructions

The description of the maintenance work is accompanied by illustrations of a general nature,

which show the sequence of work as clearly as possible. Since GHZ actuators come in various
sizes and design, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to any particular actuator.

Work on actuators should only be done by trained personnel!

GHZ Actuator SE Control unit

KS Piston rode R-SG Feedback unit

Fig. 5-2 : Actuator GHZ, Installation

Secure always the actuator unit with a lifting gear!

Pay attention the actuator unit to prevent from slipping out!
Taking care do not to scratch the valve stem with the yoke!

0342/11.01 HS Register 5-10

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E05_103794-103838.doc
1 Removing the complete actuator unit
1.1. Run the actuator unit to the mid- position of its stroke
1.2. Close the valve in the hydraulic line and drain existing accumulators
1.3. Disconnect all connectors
1.4. Disconnect all hydraulic hoses and plug all openings
1.5. Remove safety wire on articulated joint 013 and disconnect the joint
1.6. Unscrew and remove guide arm 009, unions 010,011 and coupling 008
1.7. Make a note of the distance "a" between the actuator spindle and the valve stem
1.8. Mark the position of actuator unit relative to valve
1.9. Secure the actuator unit to lifting gear, loosen and remove bolts between actuator unit and
valve 006,007
1.10. Remove actuator

2 Assembly of the complete actuator unit

2.1. Attach the complete actuator unit to lifting gear and position it on the valve, observing the
marking
2.2. Bolt the yoke to the valve, using the required torque
2.3. Connect the hydraulic hoses to the actuator.
2.4. Fill the actuator with hydraulic fluid and deaerated it
2.5. If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
actuator gets isolated from the hydraulic supply system and the remains pressurized.
In order to avoid excessive pressure increase inside the hydraulic actuator by
temperature increase of the oil in the actuator e.g. through solar radiation or
radiation from other plant components, the oil pressure of the actuators must
be released through the Minimess connections.

2.6. Re-connect and secure articulated joint 013

2.7. Check valve stroke and adjustment of position transmitter
2.8. Re-make all electrical connections
2.9. Manually operating the control unit and drive the actuator down onto the valve stem and force
the valve stem into the seat.
2.10. Drive the actuator the same distance „a“ in the "Valve open" direction, as was measured
between the actuator spindle and valve stem under Par. 1.7.
2.11. When fitting the coupling, be sure to use only coupling halves with identical markings. Be sure
that the valve stem threads exactly match those of the coupling. Tighten the coupling bolts.

Never operate actuator before tightening the coupling bolts.

Otherwise the threads of valve stem and coupling may become damaged.

0342/11.01 HS Register 5-11

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E05_103794-103838.doc
2.12. Drive the actuator travel in the "Valve open" direction until it rests against the stop. Check that
the required stroke is indicated on the scale. If not, adjust the scale.
2.13. Drive the actuator in the "Valve closed" direction until it rests against the stop. Check that the
indicator is in line with the zero mark on the scale.
2.14. If it is not, drive the actuator into its mid-position, loosen the coupling bolts and compensate
the difference by rotating the valve stem. Re-tighten the coupling bolts.

Never rotate the valve stem while it rests on the valve seat.
Otherwise the stem seating surfaces will be damaged.

2.15. Drive the actuator into its end positions "Valve open" and "Valve closed" again and check the
valve stroke against the scale readings.
2.16. If necessary, rotate the valve stem again as described above.
2.17. Tighten the coupling bolts. For the bolt tightening torques to be applied, see corresponding
Parts list in register “Sectional drawings & Parts list”.

0342/11.01 HS Register 5-12

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E05_103794-103838.doc
 STEPPING CONTROL UNIT, TYPE 4/3WEDZ3
Maintenance

Work must only be carried out on the 4/3WEDz stepping control unit if the installation is shut
down or if the relevant valve can be isolated. Even under these conditions, we recommend that
the complete stepping control unit should be replaced and that any other work should be
carried out in the comfort of a clean workshop.
This work may only be carried out by trained personnel.
All bolts and nuts must be tightened to the specified torques.

1 Replacing the complete 4/3WEDz stepping control unit

Removal:
- Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator after removal of the stepping control unit.
- Unscrew the electrical connectors (010, 011).
- Close the shut-off valves in pressure line (P).
- Release hydraulic pressure using the venting screw on the actuator.
- Unscrew hydraulic hoses.
- Unscrew and remove screws (019) and lift off the stepping control unit.
- Cleanly all hydraulic bores seal off.

Installation:
- Smear two new O-rings (009) with hydraulic fluid and place them in the grooves on the
back of the stepping control unit.
- Fit the stepping control unit with 4 screws (019) and washers.
- Connect hydraulic lines and electrical connectors.
- Slowly open the shut-off valves in the pressure line (P).
- Adjust positioning times (see section 3).

0342/11.01 HS Register 5-13

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 Item # Name of the part
009 2 O-rings Ø 17,12 x 2,62
010 1 Electrical connector (B)
011 1 Electrical connector (A)
019 4 Screws M6 x 65, SW5, Ma = 9.5 Nm

Fig. 5-3 : Replacing the complete stepping control unit & the solenoid coils

2 Replacing individual components

Replacing the solenoid coils on the installed stepping control unit

Removal:
- Separate the electrical lines, remove the electrical connectors.
- Loosen and remove the 4 socket screws.
- Lift off the stepping control unit, observe the O-rings 009.

Mounting:
- Place new O-rings 009 and attach the stepping control unit. Pay attention to the flow
direction.
- Screw in the 4 socket screws and tighten them with the indicated torque.
- Insert the electrical connectors and connect the electrical lines.

0342/11.01 HS Register 5-14

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E05_103794-103838.doc
3 Dismantling the removed stepping control unit into its main components

Dismantling:
- Loosen and remove the 3 socket screws 015.
- Lift carefully the blocks 001 and 004.

Assembly:
- Smear new O-rings (four per item 006 and 008) with hydraulic fluid and place them in the
grooves of the individual blocks.
- Restore the socket screws connection with the 3 studs 015.

Item # Name of the part Item # Name of the part

001 1 4/3-way valve 015 3 Screw M 4 x 65, SW 3, Ma = 2,7 Nm
004 1 Double throttle/ 020 1 Manifold plate
check valve
006 4 O-ring Ø 4.5 x 1.5 D Throttling adjustment screws
008 4 O-ring Ø 4.5 x 1.5 H Manual control knobs

Fig. 5-4 : Dismantling into main components & Adjusting throttling check valves

0342/11.01 HS Register 5-15

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E05_103794-103838.doc
4 Adjusting the positioning times
The positioning times for the two directions of actuator motion can be set individually with the
double throttle/check valve (004). Since throttling must always be applied to the return flow, it
is essential to check a newly installed throttling check valve block to ensure that its orientation
is correct. The orientation is correct if the identification plate is on the rear of the stepping
control unit.
- Using the manual control knobs (H), run the actuator for a full stroke and back and
measure both positioning times with a stopwatch.
- Using a spanner, adjust the setting screws (D) to give the required positioning times.
Afterwards, lock the setting screws with the locking nuts.
The arrows in the figuration indicate which throttling Check-valve acts on which direction of
motion.

Turn the screws clockwise increases the positioning time.

0342/11.01 HS Register 5-16

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 PV 4 CONTROL UNIT
Maintenance

Work must only be carried out on the PV control unit if the installation is shut down or if the
relevant valve can be isolated. Even under these conditions, we recommend that the complete
control unit should be replaced and that any other work should be carried out in the comfort of
a clean workshop.
This work may only be carried out by trained personnel.
All bolts and nuts must be tightened to the specified torques.

1 Replacing the complete PV control unit

Removal:
- Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator after removal of the control unit.
- Unscrew the electrical connectors.
- Close the shut-off valves in pressure line.
- Release hydraulic pressure using the venting screw on the actuator.
- Unscrew hydraulic hoses.
- Unscrew and remove hexagon socket screws and lift off the PV-control unit.
- Cleanly all hydraulic bores seal off.

Installation:
- Smear two new O-rings with hydraulic fluid and place them in the grooves on the back of
the PV control unit.
- Fit the PV control unit with 4 Hexagon socket screws and washers.
- Connect hydraulic lines and electrical connectors.
- Slowly open the shut-off valves in the pressure line.
If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
actuator gets isolated from the hydraulic supply system and the remains pressurized.
In order to avoid excessive pressure increase inside the hydraulic actuator
by temperature increase of the oil in the actuator e.g. through solar
radiation or radiation from other plant components, the oil pressure of the
actuators must be released through the Minimess connections.

0342/11.01 HS Register 5-17

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E05_103794-103838.doc
2 Replacing individual components

PV4_PV6k_E05-Figure.tif

Item # Part name Item # Part name

10 1 Distributor plate NG4 60 3 Screws M5 x 45 SW4,
Ma = 5.5 Nm
20 2 Screw coupling to mini-measuring 70 3 Screws M5 x 40 SW4,
device 1620 / M14 x 1.5 ED Ma = 5.5 Nm
30 2 Check valve 90 4 Screws M6 x 60 SW5,
Ma = 9.5 Nm
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG4, W 130 2 Connections for P & T

Fig. 5-5 : Replacing individual components by PV 4

All replaced valves are maintenance-free.

Faulty valves need to be replaced by new valves.

0342/11.01 HS Register 5-18

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E05_103794-103838.doc
 PV 6 CONTROL UNIT
Maintenance

Work must only be carried out on the PV control unit if the installation is shut down or if the
relevant valve can be isolated. Even under these conditions, we recommend that the complete
control unit should be replaced and that any other work should be carried out in the comfort of
a clean workshop.
This work may only be carried out by trained personnel.
All bolts and nuts must be tightened to the specified torques.

1 Replacing the complete PV control unit

Removal:
- Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator after removal of the control unit.
- Unscrew the electrical connectors.
- Close the shut-off valves in pressure line.
- Release hydraulic pressure using the venting screw on the actuator.
- Unscrew hydraulic hoses.
- Unscrew and remove hexagon socket screws and lift off the PV-control unit.
- Cleanly all hydraulic bores seal off.

Installation:
- Smear two new O-rings with hydraulic fluid and place them in the grooves on the back of
the PV control unit.
- Fit the PV control unit with 4 Hexagon socket screws and washers.
- Connect hydraulic lines and electrical connectors.
- Slowly open the shut-off valves in the pressure line.
If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
actuator gets isolated from the hydraulic supply system and the remains pressurized.
In order to avoid excessive pressure increase inside the hydraulic actuator
by temperature increase of the oil in the actuator e.g. through solar
radiation or radiation from other plant components, the oil pressure of the
actuators must be released through the Minimess connections.

0342/11.01 HS Register 5-19

Rev. 4: 06.08 Gf
E05_103794-103838.doc
2 Replacing individual components

PV6_PV8_E05-Figure.tif

Item # Part name Item # Part name

10 1 Distributor plate NG6 60 3 Screws M5 x 45 SW4, Ma = 5.5 Nm
20 2 Screw coupling to mini-measuring 70 4 Screws M5 x 50 SW4, Ma = 5.5 Nm
device 1620 / M14 x 1.5 ED
30 2 Check valve 90 4 Screws M8 x 60 SW6, Ma = 23 Nm
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG6 130 2 Connections for P & T

Fig. 5-6 : Replacing individual components by PV 6

All replaced valves are maintenance-free.

Faulty valves need to be replaced by new valves.

0342/11.01 HS Register 5-20

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E05_103794-103838.doc
 PV 6K CONTROL UNIT
Maintenance

Work must only be carried out on the PV control unit if the installation is shut down or if the
relevant valve can be isolated. Even under these conditions, we recommend that the complete
control unit should be replaced and that any other work should be carried out in the comfort of
a clean workshop.
This work may only be carried out by trained personnel.
All bolts and nuts must be tightened to the specified torques.

1 Replacing the complete PV control unit

Removal:
- Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator after removal of the control unit.
- Unscrew the electrical connectors.
- Close the shut-off valves in pressure line.
- Release hydraulic pressure using the venting screw on the actuator.
- Unscrew hydraulic hoses.
- Unscrew and remove hexagon socket screws and lift off the PV-control unit.
- Cleanly all hydraulic bores seal off.

Installation:
- Smear two new O-rings with hydraulic fluid and place them in the grooves on the back of
the PV control unit.
- Fit the PV control unit with 4 Hexagon socket screws and washers.
- Connect hydraulic lines and electrical connectors.
- Slowly open the shut-off valves in the pressure line.
If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
actuator gets isolated from the hydraulic supply system and the remains pressurized.
In order to avoid excessive pressure increase inside the hydraulic actuator
by temperature increase of the oil in the actuator e.g. through solar
radiation or radiation from other plant components, the oil pressure of the
actuators must be released through the Minimess connections.

0342/11.01 HS Register 5-21

Rev. 4: 06.08 Gf
E05_103794-103838.doc
2 Replacing individual components

PV4_PV6k_E05-Figure.tif

Item # Part name Item # Part name

10 1 Distributor plate NG6 60 3 Screws M5 x 45 SW4,
Ma = 5.5 Nm
20 2 Screw coupling to mini-measuring 70 4 Screws M5 x 50 SW4,
device 1620 / M14 x 1.5 ED Ma = 5.5 Nm
30 2 Check valve 90 4 Screws M6 x 60 SW5,
Ma = 9.5 Nm
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG6 130 2 Connections for P & T

Fig. 5-7 : Replacing individual components by PV 6k

All replaced valves are maintenance-free.

Faulty valves need to be replaced by new valves.

0342/11.01 HS Register 5-22

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E05_103794-103838.doc
 SAFETY CONTROL UNIT SSB 10Z
Maintenance

Work may only be carried out on the safety control unit SSB when the installation is shut
down. Even so, we recommend that, whenever possible, complete safety control units should
be replaced, and that any other work should be carried out in a clean workshop. .The
replacement of individual components should only be done when the unit has been removed.
This work may only be carried out by trained personnel.
All bolts and nuts must be tightened to the specified torques.

1 Replacing the complete safety control unit

Removal:
- Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator when the SSB unit is removed.
- Close the valve in pressure line (P) upstream of the stand-by accumulator and release the
pressure in the accumulator using the pressure release valve on the accumulator manifold.
- Close the valve in pressure line (P) upstream of the normal control unit (control unit PV,
stepping control unit WEDz).
- Release the pressure with the venting screw on the actuator.
- Note the arrow on control unit SSB showing the direction of the flow relative to the
actuator; disconnect hoses and connectors from the control unit.
- Unscrew and remove the four Hexagon socket screws SW6 (008) and lift off the control
unit.
- Properly seal off the hydraulic bores on actuator and control unit.

Item # Name of the part

008 4 Socket screws M6 x 100, SW5,

Ma = 9.5 Nm
009 2 O-rings Ø 17,17 x 1,78

Fig. 5-8 : Replacing the complete safety control unit SSB 10z

0342/11.01 HS Register 5-23

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 Installation:
- Smear new O-rings (009) with hydraulic fluid and insert them into the rear of the control
unit.
- Fit the control unit to the actuator, observing the direction of flow.
The arrows on the side of the control unit indicate the direction of hydraulic
fluid flow. The control unit must be positioned so that the direction of flow
corresponds to the desired actuator stroke direction when the safety
function is triggered.
- Fit the four hexagon socket screws SW5 (008) with spring washers and tighten with a
torque wrench.
- Re-connect hoses and connectors.
The P and T lines must not be confused. The connection marked P on the
control unit must always be connected to the connection marked P1 on the
accumulator manifold (the only connection on the underside).
- Slowly open all valves that were previously closed for removal.
- As soon as the stand-by accumulator is charged, activate the safety control system and
check for correct operation and direction of stroke.

2 Replacing individual components

2.1. Replacing the pilot valve
- Unscrew and remove the three hexagon socket screws SW4 (027) and lift off pilot valve
(001).
- Smear five new O-rings (021) with hydraulic fluid and insert them into the grooves of the
replacement pilot valve.
- Fit the replacement pilot valve with three Hexagon socket screws SW4 (027) and spring
washers and tighten screws with a torque wrench.

Item # Name of the part

001 1 Pilot valve
021 5 O-rings Ø 5.28 x 1.78
027 3 Socket screws M5 x 45,
SW4, Ma = 5,5 Nm

Fig. 5-9 : Replacing the pilot valve

0342/11.01 HS Register 5-24

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E05_103794-103838.doc
2.2. Replacing the releasable check valves
- Unscrew the check valve (010) with a box spanner SW36.
- Remove all O-rings from the check valve and if necessary, any that are in the bore.
- Moisten the new sealing rings (011 to 017) with hydraulic fluid and fit them to the check
valve as shown in Fig. 3.
- Carefully screw in the check valve using a box spanner SW36 and tighten.

Item # Name of the part

010 1 Releasable check valves, SW 36, Ma = 140 Nm
011 1 O-ring Ø 17.17 x 1.78
012 1 O-ring Ø 31.47 x 1.78
013 1 O-ring Ø 30.15/ 24.55 x 3.05
014 1 O-ring Ø 18.72 x 2.62
015 1 Backup ring Ø 24/19.6 x 1
016 1 Backup ring Ø 23/20.2 x 1
017 1 O-ring Ø 20.35 x 1.78

Fig. 5-10 : Replacing the releasable check valves on SSB10z

0342/11.01 HS Register 5-25

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E05_103794-103838.doc
2.3. Replacing the double check valve Half-cartridge
- Note the adjustment on the double check valve Half-cartridge 004.
- Loosen and remove the double check valve Half-cartridge.
- Moisten the new sealing ring 005 as well the cartridge with hydraulic fluid.
- Install and screw in the cartridge into the control block. Tighten it with the indicated
torque.
- Adjust the noted position of the adjusting bolt. The stroke time can only be set exactly
when the system is in operation.

Item # Name of the part

004 1 double check valve Half-cartridge SW24, Ma = 50 Nm
005 1 O-ring Ø 17.17 x 1.78

Fig. 5-11 : Replacing the double check valve Half-cartridge on SSB 10z

0342/11.01 HS Register 5-26

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E05_103794-103838.doc
 ZS STAND-BY ACCUMULATOR AND SB ACCUMULATOR MANIFOLD
Maintenance

The stand-by accumulator is delivered for safety reasons for transport

without nitrogen charging pressure.
Before commissioning all accumulators in the system have to be filled up with
nitrogen to the appropriate charging pressure.
The nominal value of the charging pressure is specified in the hydraulic data
sheet in the corresponding register.

Work may only be carried out on the SSB safety control units when the system is shut down.
We recommended working in a clean workshop if possible.
This work may only be carried out by trained personnel.
Threaded connections must be tightened to the specified torque.

1 Work on ZS stand-by accumulator

1.1. Checking the gas charge pressure
- The gas charge pressure must be checked during the normal overhaul operations. This can
be done in two ways:
- using the pressure gauge on the accumulator manifold, or
- with the pressure gauge on the nitrogen filling unit.
- The procedure for the second method is described in Section 1.2.
- The four operations described below refer only to measurement with the built-in pressure
gauge:
- Close the valve in pressure line (P) upstream of the stand-by accumulator.
- To minimise the N2 temperature loss, slowly reduce the pressure using the pressure relief
valve (022) on the accumulator manifold.
- Observe the pressure gauge: once the pressure has dropped to the N2 charging pressure (oil
fully discharged), the pressure gauge reading immediately drops to zero. The reading
before dropping is the N2 pressure.
- Set the pressure relief valve again by turning clockwise to the stop.
- Slowly open the valve in the supply line of the accumulator, the gauge reading jumps to the
N2 charging pressure
- If the N2 charging pressure is below the pressure given in the Data sheet, nitrogen must be
added (see 1.2).

0342/11.01 HS Register 5-27

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 Item # Name of the part Item # Name of the part
017 1 Pressure gauge 022 1 Pressure relief valve

Fig. 5-12 : Checking the gas charge pressure

1.2. Topping up with nitrogen
For topping up nitrogen in the gas bladder, we recommend using the special filling equipment
for Olaer accumulators.
- Unscrew the sealing cap (042) of the stand-by accumulator and take off the valve cap.
- Check the gas-tightness of the gas valve insert (044) with leak tracing spray or soap
solution. If the gas valve insert is leaking, the gas must be vented off and the insert
replaced.

Do not use a car tyre valve!

- Screw the filling unit on to the accumulator.

- Connect the filling unit hose to the nitrogen bottle.
- Close the filling unit venting valve.
- Open the valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.
- Measure the gas charge pressure: close the valve on the nitrogen bottle, screw in the
knurled screw and note the charge pressure on the filling unit pressure gauge.
- Reduce the gas charge pressure if it is too high: with the gas bottle valve closed, open the
venting valve, screw in the knurled screw and slowly open the venting valve
The charge pressure depends on the temperature. Since the filling process
affects the temperature, it is advisable to wait five minutes after the
nominal charge pressure has been reached to allow the gas temperature to
stabilize. Measure the pressure again and correct it if necessary.

0342/11.01 HS Register 5-28

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 - Close the valve on the nitrogen bottle.
- Open the venting valve on the filling unit.
- Remove the filling unit.
- Fit the valve cap (043).
- Screw on the sealing cap (042) and tighten.
- Check gas tightness with leak tracing spray or soap solution. Repair leaks immediately,
since they inevitably result in the destruction of the gas bladder in the accumulator.

Item # Name of the part Item # Name of the part

F 1 Filling unit 042 1 Sealing cap
043 1 Valve cap
024 1 Accumulator 044 1 Gas valve insert

Fig. 5-13 : Filling connector on stand-by accumulator

1.3. Replacing the complete stand-by accumulator

Removal:
- Close the valve in pressure line (P) upstream of the accumulator.
- Release the pressure in the accumulator by opening the pressure relief valve (022).
- Disconnect all hydraulic connections to the SB accumulator manifold.
- Unscrew the accumulator manifold from the accumulator.

0342/11.01 HS Register 5-29

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 - Slacken the accumulator holder clamps (040) and using lifting gear, lift the accumulator
out vertically upwards.

Installation:
- Using lifting gear, lower the replacement accumulator vertically downwards into the
accumulator holder.
- Fit the O-ring (2.1) onto the adapter nipple of the accumulator manifold.
- Screw the accumulator manifold on to the accumulator from below.

Do not over tightening the screws!

- Turn the accumulator until the accumulator manifold is correctly positioned relative to the
hydraulic connections.
- Tighten the clamps (040) and connect all hydraulic lines.
- Check the nitrogen filling pressure while accumulator is empty. If necessary, fill with
nitrogen until the filling pressure has reached the value indicated on the hydraulic data
sheet.
- Slowly open the valve in pressure line (P) and check the connections for leaks.

Item # Name of the part Item # Name of the part

2.1 1 O-ring (see drwg. 040 1 Clamps
01-EL00001-3, OLAER)
022 1 Pressure relief valve

Fig. 5-14 : Replacing the accumulator

0342/11.01 HS Register 5-30

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E05_103794-103838.doc
2 Work on the SB accumulator manifold
2.1. Setting the pressure switch (option)
The pressure switch gives an electrical signal as soon as the pressure in the accumulator drops
below the minimum setting. The pressure measurement necessary for setting the pressure
switch is done with the pressure gauge on the accumulator manifold. The pressure switch is
not standard equipment.
2.2. Measuring of pressure switch operating pressure
The operating pressure must always be measured with falling pressure. Therefore, the
accumulator must be fully filled at the beginning of the check.
- Close the valve in the pressure line (P) upstream of the accumulator.
- Slowly reduce the pressure using the pressure relief valve (022).
- Note the pressure at which the pressure switch operates. Operation of the pressure switch
can be observed on a suitable gauge connected directly to the pressure switch.
- Slowly open the valve in the pressure line (P).

0342/11.01 HS Register 5-31

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 ADJUSTMENT OF POSITION TRANSMITTER SG 15 A,
POSITION MICROSWITCHES AND POTENTIOMETER

1 General information
1.1. Types
Tab. 5-1: Tipes of abbrevetations
R - SG 15 Position transmitter
R - 4K Limit switches
R - SG 15 + 4K Position transmitter with position microswitches
R - SG 15 + 4K + P Position transmitter with position microswitches and
position potentiometer
The letter R-... signifies that the units are installed in the housing. Gas-proof position
microswitches are marked with the letters KG.
1.2. Technical specifications
- Position transmitter SG 15 (see also register 3: “Description of Main Components”,
paragraph 9.)
Tab. 5-2: Position microswitches:
type K (standard) type KG (gas-proof)
Contact ratings resistive inductive resistive inductive
Nominal voltage 220 V ~ 10 A 10 A 2.5 A 1.5 A
125 V ~ 10 A 10 A
115 V = 0.5A 0.03A 1A 0.5 A
50 V = 1A 1A
30 V = 5A 3A

Tab. 5-3: Position potentiometer

SG 15 A
Max. Ohmic resistance 1300 Ω @ 90°
Contact rating (at 40°C) 1W
Max. current for slider 120 mA
Max. angle of rotation 360°

1.3. Electrical connections

Position transmitter (+/-) and potentiometer (18-20) with AMP Fast-On 6.3
Position microswitches on terminal blocks 0.5... 2.5 mm2 (6-17)

0342/11.01 HS Register 5-32

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E05_103794-103838.doc
2 Adjustment
The exact position of the articulated joint on the position transmitter lever is set in the works.
- The distance between articulated joint and position transmitter axis must be equal to the
valve stroke (see valve data sheet).
- At 50 % valve stroke, the lever should be almost horizontal. If not, correct the adjustment
using the connecting bolt between the articulated joints.
To adjust the position transmitter, the position microswitches and the potentiometer, loosen the
two screws and remove the cover. The actuator must be free to operate over its entire stroke
(see valve data sheet). The position transmitter module in the control cubicle must be operable.
2.1. Position transmitter
- Operate the actuator until it reaches the position where the position signal has its minimum
value. This is normally the "valve closed" position.
- Check that about 24 VDC is available across the +/- terminals with the correct polarity.
- Connect an ammeter with a range of at least 0 to 20 mA, in series with the position
transmitter. For this purpose the + line is to be disconnected and connected to the
instrument. The second instrument connection is to be attached to the open terminal on the
position transmitter.
- Operate actuator until it just moves away from its end position and observe the direction of
rotation of the position transmitter shaft. Operate actuator back to its starting position.
- Loosen the lock nut on the position transmitter shaft and find the minimum current position
by rotating the shaft.
- Set the potentiometer Io counter-clockwise (ccw) to the minimum and ∆ I clockwise (cw)
to the maximum. Rotate position transmitter shaft ccw to the minimum (for an increasing
curve, cw for a decreasing curve) and then rotate cw (ccw for a decreasing curve) until the
current increases suddenly. Make correction ccw (cw for a decreasing curve) in order to
reach the minimum current again (the start of the linear portion of the characteristic, also
see data sheet).
- Tighten the lock nut on the position transmitter shaft (be sure that the shaft does not rotate).
- Operate the actuator slowly from its starting position, whereby the mA signal must rise
immediately. If this is not the case then the position transmitter shaft has slipped during
tightening the lock nut, and the mechanical adjustment procedure has to be repeated.
- Operate the actuator back to the "valve closed" position. Set the zero current to 4 mA or 5
mA using the potentiometer Io.
- Operate the actuator to the opposite end position "valve open", and set the corresponding
current to 20 mA or 15 mA using the potentiometer ∆ I.
- As a double check, run the actuator to both of its end positions and, if necessary, correct the
zero current using Io and the amplification using ∆ I.
- Run the actuator back to its starting position "valve closed".
- Disconnect the ammeter and reconnect the position transmitter.

0342/11.01 HS Register 5-33

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E05_103794-103838.doc
2.2. Position microswitches
Each limit switch is set individually, the procedure being the same for each.
- Run the actuator in the direction in which it operates the switch, until the intended
switching position has been reached. While doing so observe the rotational direction of the
shaft.
Rotate the corresponding cam in the same direction until the required switching action takes
place.
Depending on which half of the cam profile is used, pressing or releasing of
the switch lever results. The cam is rotated with the adjusting lever located
on the frame. It is sufficient that only one pin engages with one of the cam
plate holes and that the other is in contact with cam plate profile. It is not
necessary to lock the cam plates; they are kept in position by disc springs.

2.3. Position potentiometer

The potentiometer is coupled to the position transmitter drive shaft .
- Run the actuator to the end position at which the slidewire connection of the potentiometer
gives 0 Ohm.
- Run the actuator until it just moves away from its end position and observe the rotational
direction of the drive shaft. Run the actuator back to its starting position.
- Insert a screwdriver into the free shaft end and rotate the potentiometer in the opposite
direction until the stop is felt.
The resistance between one end of the potentiometer winding and the
slidewire connection increases when the actuator is operated toward the
other end position. The maximum resistance value reached is dependent
on the angle of rotation. The polarity of the end connections, 18 and 20,
must be checked.

0342/11.01 HS Register 5-34

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E05_103794-103838.doc
 INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER

The position transmitter 2,0 is fitted with a damping element 1,1 to minimise vibration from
the actuator yoke.

Fitting
- Loosen screw 4,2 and remove lever 4,1 from the dummy shaft.
- Remove the dummy.
- Fit position transmitter to the yoke, using screws 1.6 and washers 1,5.
- Slide lever 4,1 onto the shaft of position transmitter and tighten the screw 4,2.
- Adjust the position transmitter according to Instruction "Setting-up the Feedback unit with
Position Transmitter SG 15 A/B, Position Microswitches and Potentiometer".

Removing
- Loosen screw 4,2 and remove lever.
- Loosen and remove screws 1,6 and washers 1,5.
- Replacing the damping element
- Remove the position transmitter as above describd.
- Loosen the screws 1,4 and remove the damping element 1,1, rubber discs 1,2 and washers
1,3
- Clean and fit new damping elements, rubber discs, screws and washers if necessary.

Fig. 5-15 : Instructions for fitting and removing the position transmitter

0342/11.01 HS Register 5-35

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 WIRING DIAGRAM OF THE POSITION MICROSWITCHES INSIDE POSITION TRANSMITTERS

Colour of wires:

gn = green
rt = red
ws = white

SG = position transmitter

Fig. 5-16 : Wiring diagram of the position microswitches inside position transmitters

0342/11.01 HS Register 5-36

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 SERVICE RECORDS
Kunde / Customer
Anlage / Plant
Ventil-Bez. / Valve identification
Anlagen-Ventilbez. / Plant valve TAG
CCI-Ventil Nr. / CCI-Valve No.
Installationsdaten / Erection date Datum /Date Vis. / Sig. Bemerkungen / Notes
Montage / Assembly
Inbetriebsetzung / Commissioning
Zeitplan / 1) Tätigkeiten / Activities Datum/Date Vis./Sig. Bem./ Notes
Schedule
1stes Jahr + Ventil / Valve: General inspection ---- ---- ----
alle 2 Jahre Kontrolle des Strahlfängerkorbes und
1st year + Ventilsitzes, Ersatz der Dichtungen und
every 2 years Packungen / Check jet cage and valve
seat, replace sealing rings and packings
Antrieb / Actuator: General inspection
Visuelle Leckagekontrolle, Kontrolle
des Positionierkreises / Visual check of
leakage, check positioner loop
alle 6 Jahre Antrieb / Actuator: ---- ---- ----
every 6 years Hydraulikschläuche austauschen /
Replace hydraulic hoses
alle 10 Jahre Antrieb / Actuator: ---- ---- ----
every 10 Alle Dichtungen austauschen / Replace
years all sealing rings
Zeitplan / 1) Tätigkeiten / Activities Datum/Date Vis./Sig. Bem./Notes
Schedule
1. Allg. Inspektion / General inspection

1) Siehe auch: "Empfehlungen für Revisions-Intervalle an CCI AG / SULZER-Regelventilen", sowie

Vorschriften der zuständigen lokalen Behörden. Für weitere Informationen, sich wenden an:

1) See also: "Recommendations for overhaul intervals for CCI AG / SULZER-control valves", and
also consult the regulations of the responsible local Authorities. For further information, contact:

Kundendienst / Customer Service

CCI AG
Im Link 11; P.O. Box 65
CH-8404 Winterthur
Schweiz / Switzerland

0342/11.01 HS Register 5-37

Rev. 4: 06.08 Gf
E05_103794-103838.doc
 FIGURES CONTENTS REGISTER 5
FIG. 5-1 : EXAMPLE OF BOLT TIGHTENING SEQUENCE 8
FIG. 5-2 : ACTUATOR GHZ, INSTALLATION 10
FIG. 5-3 : REPLACING THE COMPLETE STEPPING CONTROL UNIT & THE SOLENOID COILS 14
FIG. 5-4 : DISMANTLING INTO MAIN COMPONENTS & ADJUSTING THROTTLING CHECK VALVES 15
FIG. 5-5 : REPLACING INDIVIDUAL COMPONENTS BY PV 4 18
FIG. 5-6 : REPLACING INDIVIDUAL COMPONENTS BY PV 6 20
FIG. 5-7 : REPLACING INDIVIDUAL COMPONENTS BY PV 6K 22
FIG. 5-8 : REPLACING THE COMPLETE SAFETY CONTROL UNIT SSB 10Z 23
FIG. 5-9 : REPLACING THE PILOT VALVE 24
FIG. 5-10 : REPLACING THE RELEASABLE CHECK VALVES ON SSB10Z 25
FIG. 5-11 : REPLACING THE DOUBLE CHECK VALVE HALF-CARTRIDGE ON SSB 10Z 26
FIG. 5-12 : CHECKING THE GAS CHARGE PRESSURE 28
FIG. 5-13 : FILLING CONNECTOR ON STAND-BY ACCUMULATOR 29
FIG. 5-14 : REPLACING THE ACCUMULATOR 30
FIG. 5-15 : INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER 35
FIG. 5-16 : WIRING DIAGRAM OF THE POSITION MICROSWITCHES INSIDE POSITION TRANSMITTERS 36

TABLES CONTENTS REGISTER 5

TAB. 5-1: TIPES OF ABBREVETATIONS 32
TAB. 5-2: POSITION MICROSWITCHES: 32
TAB. 5-3: POSITION POTENTIOMETER 32

0342/11.01 HS Register 5-38

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E05_103794-103838.doc
 REGISTER 6
DISMANTLING & ASSEMBLY
HP STEAM CONTROL VALVE HBSE 280 - 250 201335-1CH
LP STEAM CONTROL VALVE NBSE 60 - 400 - 2 201335-4CH
LP STEAM ISOLATION VALVE NA 60 - 600 201335-5CH

Contents

HYDRAULIC ACTUATORS GHZ & GHZF 3

1 GENERAL INSTRUCTIONS 3
2 PISTON ROD GASKETS 5
3 DISMANTLING INTO INDIVIDUAL PARTS 5
4 ASSEMBLY 6
5 FITTING INSTRUCTIONS FOR INDIVIDUAL COMPONENTS INSTALLATION 8

HP – BP STEAM CONTROL VALVE HBSE 280 - 250 9

1 GENERAL NOTES 9
2 DISMANTLING 10
3 ASSEMBLING 14
4 LAPPING THE VALVE SEAT 16
5 ELECTRICAL CONNECTIONS 16

LP – BP STEAM CONTROL VALVE NBSE 60 – 400 - 2 17

1 GENERAL NOTES 17
2 DISMANTLING 18
3 ASSEMBLING 22
4 LAPPING THE VALVE SEAT 24
5 ELECTRICAL CONNECTIONS 24

LP – BP STEAM ISOLATION VALVE NA 60 - 600 25

1 GENERAL NOTES 25
2 DISMANTLING 26
3 ASSEMBLING 30
4 LAPPING THE VALVE SEAT 32
5 ELECTRICAL CONNECTIONS 32

INSTALLATION AND RETIGHTENING OF “GARLOCK 9000 EVSP” PACKING RINGS 33

730/04.05 Gf Register 6-1

E06_103794-103838.doc
INSPECTION AND EXCHANGE OF THE WATER INJECTING NOZZLE,
RETIGHTENING OF GRAPHITE PACKUNG RINGS 35
1 IMPORTANT NOTES 35
2 DISASSEMBLY OF WATER INJECTING NOZZLES 35
3 RE-ASSEMBLY OF WATER INJECTING NOZZLES 36
4 RE-TIGHTENING OF GRAPHITE PACKING RINGS 37

FAULT-FINDING AND RECOMMENDED REPAIR FOR VALVES AND ACTUATORS 39

FIGURES CONTENTS REGISTER 6 40

TABLE CONTENTS REGISTER 6 40

730/04.05 Gf Register 6-2

E06_103794-103838.doc
 HYDRAULIC ACTUATORS GHZ & GHZF
Dismantling and Assembly Instructions

These instructions are intended for the execution of maintenance and cleaning works as well as
for the replacement of packing kits or seal rings.

Binding descriptions:
“Descriptions of the main component” in register 3.
“General maintenance instructions” in register 5.

Faulty or damaged actuators are to be completely replaced!

1 General Instructions
- Checks to be carried out before starting work:
- The valve must be depressurized.
- All electric supply lines must be de-energised.
- The piping system to the hydraulic actuators must be depressurized
- When several valves are dismantled at the same time, care must be taken that the parts
from different valves are not mixed up.
- Before the assembly, all parts are to be cleaned and inspected for possible damages.
- When assembling, use only new gaskets.
- Screw connections must be done as described in the “General maintenance instructions”.
The tightening torqueses apply to correctly lubricated bolts and nuts at room temperature.

All repair and maintenance works on actuators must

only be carried out by qualified and trained personnel.

1.1. Figures and illustrations

The description of the maintenance work is accompanied by illustrations of a generally
applicable nature, which show the sequence of work as clearly as possible. Since valves come
in various sizes, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to a particular valve. For further information to
a single position please consider the corresponding drawing and parts list.

1.2. Maintenance
Works that have to be carried out on the actuator are only possible, if the installation is not in
operation at that time or if the corresponding valve can be isolated.
We strongly recommend that no maintenance work should be done on actuators in situ. Large
amounts of hydraulic fluid are almost certain to escape. Wherever possible, actuators should be
removed complete and dismantled in a clean workshop. This has the additional advantage that
the actuator can always be dismantled in the upright position, which makes the work far easier.

730/04.05 Gf Register 6-3

E06_103794-103838.doc
 If for some reason the drive that requires maintenance cannot be removed complete, an attempt
can be made - depending on the mounting position of the actuator - to draw off at least some of
the hydraulic fluid with a suitable pump. Large collecting trays will still need to be provided
and the greatest possible care must be taken.
Warning: when removing the piston rod, remember that
the fluid behind the piston will escape!

GHZ_Explosionsbild-komplett.tif

Fig. 6-1 : Exploded view GHZ/ GHZF actuators

In site:
- Make sure that the medium (e.g. steam) is not exerting any forces on the valve stem.
- If the actuator is equipped with a hydraulic stand-by accumulator:
- Close the valve in the pressure line to the accumulator and drain the accumulator to the
tank via the release valve in the accumulator manifold.

In the workshop:
- Prepare a collecting pan in which the valve actuator unit (actuator plus yoke) can be stood
upright.
- Prepare ether works area so that there are sufficient clean surfaces for all materials.

Extreme cleanliness must be observed when replacing seals!

730/04.05 Gf Register 6-4

E06_103794-103838.doc
2 Piston rod gaskets

2.1. Design for “Mineral Oils”

Actuators, type GHZ

Pos. Name of Parts
003 1 Hydraulic cylinder head
004 1 Threaded short bushing
020 2 Guide rings
021 1 Piston rod seal, Polypac-Selmaster
022 1 Scraper ring Lubroseal

Fig. 6-2 : Piston rod gasket, design for „ Mineral Oil“

2.2. Design for “Phosphate Ester Fluid”

Actuators, type GHZF

Pos. Name of Parts

003 1 Hydraulic cylinder head

004 1 Threaded bush
017 1 O-ring, Viton
020 2 Guide rings, Viton
021 2 Piston rod Turcon Stepseal
with O-rings, Viton
022 1 Scraper ring Turcon Excluder
with O-ring, Viton

Fig. 6-3 : Piston rod gasket, design for „ Phosphate Ester Fluid “

3 Dismantling into individual parts

- Disassemble the actuator from the valve and put it into a tray.
- Dismount the existing control unit from the cylinder plate. The connection openings of the
control unit are to be closed by means of plugs.
- Loosen the bleeder screw 010 on the cylinder plate.
- Loosen and remove the screw connections on the hydraulic tube.

Caution:
Hydraulic fluid flows out!

- Loosen the screw connection 012 between the cylinder head and the cylinder tube.

730/04.05 Gf Register 6-5

E06_103794-103838.doc
 - The mounting group: carefully draw the complete piston rod and piston, the complete
cylinder head with the short bushing and seals out of the cylinder tube.
- Dismantle the mounting group into its individual parts. Remove all seals from the short
bushing.
- Loosen and remove the screw connection 011b between the cylinder plate and the cylinder
tube.
- Carefully take the cylinder plate out of the cylinder tube. Remove the O-ring 016.
- Clean all parts thoroughly and check them for damages.

4 Assembly

4.1. Piston
- The piston is screwed to a piston rod, locked with set screw and secured with Loctite, so
that they build a single mounting group.

In case of damages or wear and tear, the mounting group must be replaced in its entirety.

4.2. Replacement of piston seal kit 019

- Provide a new piston seal kit.
- Dismantle the piston seal kit in its individual parts. Moisten all parts with hydraulic fluid
and fit them on the piston by means of an appropriate device.
- For a suggestions for a mounting device, see section 5, “Fitting instructions for individual
components installation”.

4.3. Assembly of the cylinder head: Mineral oil

Provide new seals.
- Thoroughly clean and degrease the female thread of the cylinder head.
- Moisten the new guide ring 020 with hydraulic fluid and pace it into the threaded short
bushing.
- Moisten a new set of Piston rod packing 021 with hydraulic fluid and insert them into the
cylinder head according to the drawing.
- Equip the cylinder head with a new O-ring 016.
- Equip the short bushing with new seals according to the figure shown in paragraph 2.1.
- Disperse some drops of Loctite No. 243 on the perimeter of the bushing’s thread; then
screw it to the bottom of the cylinder head and tighten it.
- Moisten all seals in the cylinder head with hydraulic fluid.
- Equip the cylinder head with a greased O-ring 016.
- Build a cylinder head mounting group. Carefully fit the complete cylinder head to the
single mounting group (piston rod with piston).

Do not damage the cylinder head seals with the piston rod thread.

730/04.05 Gf Register 6-6

E06_103794-103838.doc
4.4. Assembly of the cylinder head: Phosphate Ester Fluid
Provide new Viton seals.
- Follow the procedures described in the “Mineral oil”, refer to the chapter 4.3.
- However, the threaded bush must be equipped with seals of corresponding quality. Refer to
the figure 6-2 or to the parts list with picture in the corresponding register.

4.5. Assembly of the cylinder head mounting group and the cylinder tube
- Moisten the inside of the cylinder tube slightly with hydraulic fluid.
- Grease the cylinder tube surface along the entire perimeter.
- Grease the piston seal on the outer perimeter.
- Carefully introduce the cylinder head mounting group into the cylinder tube.
- Insert the screws 012 between the cylinder head and the cylinder tube.
- Tighten the screws crosswise. Refer to the Table 6-1 for the corresponding torque.
- Pre-assemble the angular screw plug 040, but do not tighten it.

4.6. Pre-assembly of the cylinder bottom

- Equip the cylinder bottom with a greased O-ring 016.
- Equip the cylinder bottom with a straight 041 or an angular screw plug 040, depending on
the type of actuator.
- Introduce the hydraulic tube 042 into the screw plug and tighten it.

4.7. Assembly of the cylinder bottom and the cylinder tube

- Grease the cylinder tube surface along the entire perimeter.
- Carefully introduce the cylinder bottom into the cylinder tube and simultaneously introduce
the hydraulic tube into the angular screw joint on the cylinder head.
- Insert the screws 011 between the cylinder bottom and the cylinder tube.
- Tighten the screws crosswise. Please see Table 1 for the appropriate torque.
- Tighten the angular screw joint 040.
- Screw in and tighten the locking screw 010.
Tab. 6-1: Recommended torque values of the screws

Type of cylinder Screws / Mat. Torque Comment

GHZ-50/20-… V M8 x 30 / DIN 912 8.8 24 Nm Slightly greased.
GHZ-63/20-… V M8 x 30 / DIN 912 8.8 24 Nm Slightly greased.
GHZ-80/30-… V M10 x 30 / DIN 912 8.8 48 Nm Slightly greased.
GHZ-100/30-… V M12 x 40 / DIN 912 8.8 83 Nm Slightly greased.

730/04.05 Gf Register 6-7

E06_103794-103838.doc
5 Fitting instructions for individual components installation

Insert piston into the device. Moisten lightly Snap the main seal, in accordance to Fig. 2,
the main seal and introduce it to the piston as in.
shown in Fig. 1

The main seal is full sitting in the groove. Snap in the angular guide rings.
Remove the piston off the device. The seal set is completely installed.

Fig. 6-4 : Fitting of the individual piston seal components

730/04.05 Gf Register 6-8

E06_103794-103838.doc
 HP – BP STEAM CONTROL VALVE HBSE 280 - 250
Instructions for Dismantling and Assembling

Relevant Drawings:
Top assembly drawing: 201335-1CH Production drawing: 103.232.426.500 Design: 200

Relevant Instructions in Register:

“General Maintenance Instructions”:
- “Revisions Intervals for CCI AG Valves”
- “Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER
Valves”.
- “Removing the complete Actuator unit”
- “Assembly of the complete actuator unit”

In this Register:
- „Installation and Retightening of GARLOCK 9000 EVSP packing rings".
- „Inspection and Exchange of the Water Injecting Nozzle”.

1 General Notes

Checks to be carried out before starting work:

- The valve must be depressurized, allowed to cool down to ambient temperature and drained.
- All electrical wires and cables must be de-energized.
- The piping system to hydraulic actuators must be depressurized.
- Hydraulic actuator ASM / GHZ, Instructions for Dismantling and Assembly.
During electrical operation certain parts inevitably carry lethal voltages.
To avoid personal injury and damage to the process system, disconnect
the equipment from all electric power lines.

1.1. When several valves are dismantled at the same time, care must be taken that the parts from
different valves are not mixed up.
1.2. Prior to assembly, all parts are to be cleaned and inspected for possible damage.
1.3. When assembling, use only new gaskets.
1.4. Bolted connections must be done as described in the general maintenance instructions.
The tightening torques for bolts and nuts are given in the corresponding
drawings, mounting instructions or spare parts lists. The tightening torques
applies to correctly lubricated bolts and nuts at room temperature.

730/04.05 Gf Register 6-9

E06_103794-103838.doc
 The description of the maintenance work is accompanied by illustrations of a generally
applicable nature, which show the sequence of work as clearly as possible. Since valves come
in various sizes, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to a particular valve. For further information
to a single position please consider the corresponding drawing and parts list.

2 Dismantling

Connection Actuator-Yoke-Valve vertical.tif

Fig. 6-5 : Actuator unit

2.1. Dismantling the actuator unit

Disassembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 1 “Removing the complete actuator unit”.
Secure always the actuator unit with a lifting gear!
Pay attention the actuator unit to prevent from slipping out!
Taking care not to scratch the valve stem with the yoke!

730/04.05 Gf Register 6-10

E06_103794-103838.doc
2.2. Dismantling the valve

For security reasons must for handling and relocation of the individual parts,
on account of their weights, suitable tools and means of transport used.

Secure always the bonnet and all parts of the valve insert against slipping out!

HBSE-NBSE_inserts_vertical.tif

Fig. 6-6 : Valve Inserts HBSE 280 - 250

2.2.1. Bend back the locking plates. Loosen and remove the nuts, the packing flange and the gland
bush.
2.2.2. Push slowly the plug unit into the valve seat.
2.2.3. Using an eye bolt secure the bonnet assembly to lifting gear.
2.2.4. Loosen and remove the nut connection between the bonnet and valve body using the pattern
described in the “GENRAL MAINTENANCE INSTRUCTIONS”.
2.2.5. Pull out the bonnet assembly using the forcing bolts from the valve body.
2.2.6. Remove the forcing bolts, if necessary.

730/04.05 Gf Register 6-11

E06_103794-103838.doc
2.2.7. Remove carefully the bonnet assembly, over the valve stem, off the valve body.
Make sure, that the valves insert remains in the valve body.

Taking care not to scratch and bend the valve stem!

Observe the position cylindrical pin, if provided, into

the bonnet versus the bore in the valve body!

2.3. Removing the Packing set

2.3.1. Remove the packing set from the bonnet. Use a bar stock of the same diameter as the valve
stem. An air blast is usually helpful in removing all loose material. Refer to the Figure
“Packing removal”.
2.3.2. Remove the packing spacer only if necessary.

Fig. 6-7 : Packing removal

Do not to damage the packing box!

2.4. Removing the valve insert

2.4.1. Pull out the inlet cage of the valve body. If lifting holes are provided, attach two eye bolts and
a sling. Remove carefully the inlet cage together with the upper packing ring and the stem /
plug unit off the valve. Refer to the Figure “Lifting arrangement of valve insert”.

Be careful about the mating surfaces of all parts of the valve insert.
Do not damage, scratch or bend the valve stem!

2.4.2. Separate with care the stem / plug unit from the inlet cage.
2.4.3. If necessary, carefully pull the valve seat out of the valve body as well. If lifting holes are
provided, attach two eye bolts and a sling. Remove the valve seat; together with the lower
packing ring. Refer to the Figure “Lifting arrangement of valve insert”.

730/04.05 Gf Register 6-12

E06_103794-103838.doc
 Take care not to damage some
mating surfaces of any parts!

Fig. 6-8 : Lifting arrangement of valve insert

2.4.4. Thoroughly clean all parts and check them for damage.
2.4.5. Inspect the seating surfaces of the valve stem and valve seat for damage. If necessary,
recondition seat and stem by lapping, respectively by grinding, in case of major damage.
2.5. Dismantling the plug unit

Never divide the plug into his individual parts!

2.6. Dismantling the balance seal or packing ring, if existing.

Dismantle the plug assembly only

if it necessary!

Fig. 6-9 : Balance seal

2.6.1. Remove the lock wire with pliers.

2.6.2. Loosen and remove the socket head screws in accordance to the “Instructions for Bolt Thread
Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
2.6.3. Separate the Retainer ring and the balance seal packing ring from the plug

730/04.05 Gf Register 6-13

E06_103794-103838.doc
3 Assembling

Apply lubricant to the all studs, bolts, nuts and washers as well as to threaded holes of the
valve, in accordance with the “GENRAL MAINTENANCE INSTRUCTIONS”.
DO NOT LUBRICATE THE INSERT PARTS WITH ANY GREASE!
Apply pure Graphite or Molybdenum-Disulphide powder to all surfaces
which have metal-to-metal contact.

In case previously dismantled:

- Install packing spacer and lower it to the bottom of bonnet stuffing box.
- In case of prior removal of studs and threaded studs, install them in accordance to the
General Maintenances Instructions: “Instructions for Bolt Thread Lubrication and Torque
Settings”. Make sure, that they are fully screwed to the bottom of the threaded holes.
- Place the position cylindrical pin into the bonnet, if provided.
3.1. Assembly the balance seal, if existing.
3.1.1. Place a new balance seal over the stem on the plug, attach the packing retainer ring and fasten
them with the head stud. Tighten the studs by hands. Refer to figure “Balance seal”

Taking care not to scratch and bend the valve stem with the mounting tools!

3.1.2. Insert with care the plug unit into the inlet cage. Press it into the back seat and secure against
moving.
3.1.3. Tighten the studs using the method and pattern described in the “GENERAL
MAINTENANCE INSTRUCTIONS”, with torque specified in the Top assembly drawing.
3.1.4. Lock the studs with steel wire. Refer to the figure “Balance seal
3.2. Assembly the valve

This work required a clean work area:

- Re-check the position of the packing spacer and of the position cylindrical pin, if provided.
- Place the stem with plug perpendicularly on the soil.
- Carefully install, using two eye bolts and lifting gear, the inlet cage over the plug. Slide the
plug into the back seat and secure it against moving.
3.2.1. In case previously dismantled, insert carefully new lower packing ring to the valve seat and
lower them to the bottom of valve body recess. If lifting holes are provided, attach two eye
bolts and a sling.
3.2.2. Carefully install the inlet cage complete into the annular groove between valve body and seat.
If lifting holes are provided, attach two eye bolts and a sling.

Never rotate the inlet cage while resting on packing ring!

3.2.3. Loosen the plug clamp and lower it slowly onto the valve seat.
730/04.05 Gf Register 6-14

E06_103794-103838.doc
 Never rotate the valve stem while resting on the valve seat.
Otherwise the sealing surfaces of the stem and seat may become damaged.

3.2.4. Check whether contact surfaces of bonnet and valve inside are clean, and without any
damages.
3.2.5. Install a new upper packing ring to the bonnet.
3.2.6. By means of lifting gear attached with care the bonnet, over the plug stem, to the valve body.
Observe the mark and position cylindrical pin into the bonnet, if provided,
versus the bore in the valve body!
Never rotate the bonnet while resting on packing ring!
Do not bend or damage the stem and the mating surfaces!

3.2.7. Restore the nuts / bolts connection between the bonnet and valve body. Tighten them
alternating crosswise in accordance to the “GENRAL MAINTENANCE INSTRUCTIONS”.
3.2.8. With a feeler gauge, check that the bonnet has metal-to-metal contact with the valve body. If
not, re-tighten the lower packing ring until contact is achieved. Re-check the metal-to-metal
contact between the bonnet and the valve body.
3.2.9. Restore required tightening torque of the bolts or nut connection. For the specified torque of
the bolts or nuts refer to the Top assembly drawing or the Parts list.
3.2.10. Recheck metallic tightness between bonnet and valve body with feeler gauge.
3.3. Assembly of the gland
3.3.1. Have a new packing set, the gland bush and gland flange readily available.
3.3.2. The procedure for installing and compressing of packing rings is given in: „Installation and
Retightening of GARLOCK 9000 EVSP packing rings”.
For safety reasons, studs must protrude
from nuts by at least 2 threads.

3.4. Assembling the actuator unit

3.4.1. Apply lubricant to the bolted connection between yoke and valve body, according to the
“Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
3.4.2. Fit the oil drip pan, if provided.
3.4.3. Assembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 2 “Assembly the complete actuator unit”.

730/04.05 Gf Register 6-15

E06_103794-103838.doc
4 Lapping the valve seat

Dismantling the actuator unit is done according to “GENRAL MAINTENANCE

INSTRUCTIONS”, in instruction “Removing the complete actuator unit GHZ/ GHZF or
ASM”.
4.1. Disassembly the valve inserts as instructed in Section 2.2., Par. 2.2.1 to 2.2.7.
4.2. Remove the Packing set in acc. to Section 2.3.
4.3. Insert the valve stem as well as the packing spacer into the bonnet and attach this assembly
unit to a lifting gear.

Secure always the assembly unit with a lifting gear!

4.4. Apply lapping paste.

4.5. Using lifting gear, carefully insert the assembly unit on the valve stem 010 into the valve body.

Observe the position cylindrical pin, if provided, into the bonnet versus
the bore in the valve body!

4.6. At horizontal installation of valve, bolt down the bonnet at least with 3 bolts or nuts in order to
make sure of metallic contact to the valve body.
4.7. Slowly lowered the stem into the valve seat.
4.8. Repeat lapping and blue ink testing until desired result reached.
4.9. Thoroughly clean and check all parts for damage again.
4.10. Assembly is done in accordance with Section 3.

5 Electrical connections

5.1. Re-make all electrical connections.

5.2. Check that the direction of actuator movement is correct.
5.3. Check the position transmitter and re-adjust it if necessary.
5.4. Carry out a functional test.

730/04.05 Gf Register 6-16

E06_103794-103838.doc
 LP – BP STEAM CONTROL VALVE NBSE 60 – 400 - 2
Instructions for Dismantling and Assembling

Relevant Drawings:
Top assembly drawing: 201335-4CH Production drawing: 103.232.424.500 Design: 200

Relevant Instructions in Register:

“General Maintenance Instructions”:
- “Revisions Intervals for CCI AG Valves”
- “Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER
Valves”.
- “Removing the complete Actuator unit”
- “Assembly of the complete actuator unit”

In this Register:
- „Installation and Retightening of GARLOCK 9000 EVSP packing rings".
- „Inspection and Exchange of the Water Injecting Nozzle”.

1 General Notes

Checks to be carried out before starting work:

- The valve must be depressurized, allowed to cool down to ambient temperature and drained.
- All electrical wires and cables must be de-energized.
- The piping system to hydraulic actuators must be depressurized.
- Hydraulic actuator ASM / GHZ, Instructions for Dismantling and Assembly.
During electrical operation certain parts inevitably carry lethal voltages.
To avoid personal injury and damage to the process system, disconnect
the equipment from all electric power lines.

1.1. When several valves are dismantled at the same time, care must be taken that the parts from
different valves are not mixed up.
1.2. Prior to assembly, all parts are to be cleaned and inspected for possible damage.
1.3. When assembling, use only new gaskets.
1.4. Bolted connections must be done as described in the general maintenance instructions.
The tightening torques for bolts and nuts are given in the corresponding
drawings, mounting instructions or spare parts lists. The tightening torques
applies to correctly lubricated bolts and nuts at room temperature.

730/04.05 Gf Register 6-17

E06_103794-103838.doc
 The description of the maintenance work is accompanied by illustrations of a generally
applicable nature, which show the sequence of work as clearly as possible. Since valves come
in various sizes, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to a particular valve. For further information
to a single position please consider the corresponding drawing and parts list.

2 Dismantling

Connection Actuator-Yoke-Valve vertical.tif

Fig. 6-10 : Actuator unit

2.1. Dismantling the actuator unit

Disassembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 1 “Removing the complete actuator unit”.
Secure always the actuator unit with a lifting gear!
Pay attention the actuator unit to prevent from slipping out!
Taking care not to scratch the valve stem with the yoke!

730/04.05 Gf Register 6-18

E06_103794-103838.doc
2.2. Dismantling the valve

For security reasons must for handling and relocation of the individual parts,
on account of their weights, suitable tools and means of transport used.

Secure always the bonnet and all parts of the valve insert against slipping out!

HBSE-NBSE_inserts_vertical.tif

Fig. 6-11 : Valve Inserts NBSE 60 – 400 - 2

2.2.1. Bend back the locking plates. Loosen and remove the nuts, the packing flange and the gland
bush.
2.2.2. Push slowly the plug unit into the valve seat.
2.2.3. Using an eye bolt secure the bonnet assembly to lifting gear.
2.2.4. Loosen and remove the nut connection between the bonnet and valve body using the pattern
described in the “GENRAL MAINTENANCE INSTRUCTIONS”.
2.2.5. Pull out the bonnet assembly using the forcing bolts from the valve body.
2.2.6. Remove the forcing bolts, if necessary.

730/04.05 Gf Register 6-19

E06_103794-103838.doc
2.2.7. Remove carefully the bonnet assembly, over the valve stem, off the valve body.
Make sure, that the valves insert remains in the valve body.

Taking care not to scratch and bend the valve stem!

Observe the position cylindrical pin, if provided, into

the bonnet versus the bore in the valve body!

2.3. Removing the Packing set

2.3.1. Remove the packing set from the bonnet. Use a bar stock of the same diameter as the valve
stem. An air blast is usually helpful in removing all loose material. Refer to the Figure
“Packing removal”.
2.3.2. Remove the packing spacer only if necessary.

Fig. 6-12 : Packing removal

Do not to damage the packing box!

2.4. Removing the valve insert

2.4.1. Pull out the inlet cage of the valve body. If lifting holes are provided, attach two eye bolts and
a sling. Remove carefully the inlet cage together with the upper packing ring and the stem /
plug unit off the valve. Refer to the Figure “Lifting arrangement of valve insert”.

Be careful about the mating surfaces of all parts of the valve insert.
Do not damage, scratch or bend the valve stem!

2.4.2. Separate with care the stem / plug unit from the inlet cage.
2.4.3. If necessary, carefully pull the valve seat out of the valve body as well. If lifting holes are
provided, attach two eye bolts and a sling. Remove the valve seat; together with the lower
packing ring. Refer to the Figure “Lifting arrangement of valve insert”.

730/04.05 Gf Register 6-20

E06_103794-103838.doc
 Take care not to damage some
mating surfaces of any parts!

Fig. 6-13 : Lifting arrangement of valve insert

2.4.4. Thoroughly clean all parts and check them for damage.
2.4.5. Inspect the seating surfaces of the valve stem and valve seat for damage. If necessary,
recondition seat and stem by lapping, respectively by grinding, in case of major damage.

2.5. Dismantling the plug unit

Never divide the plug into his individual parts!

2.6. Dismantling the balance seal or packing ring, if existing.

Dismantle the plug assembly only

if it necessary!

Fig. 6-14 : Balance seal

2.6.1. Remove the lock wire with pliers.

2.6.2. Loosen and remove the socket head screws in accordance to the “Instructions for Bolt Thread
Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
2.6.3. Separate the Retainer ring and the balance seal packing ring from the plug

730/04.05 Gf Register 6-21

E06_103794-103838.doc
3 Assembling

Apply lubricant to the all studs, bolts, nuts and washers as well as to threaded holes of the
valve, in accordance with the “GENRAL MAINTENANCE INSTRUCTIONS”.
DO NOT LUBRICATE THE INSERT PARTS WITH ANY GREASE!
Apply pure Graphite or Molybdenum-Disulphide powder to all surfaces
which have metal-to-metal contact.

In case previously dismantled:

- Install packing spacer and lower it to the bottom of bonnet stuffing box.
- In case of prior removal of studs and threaded studs, install them in accordance to the
General Maintenances Instructions: “Instructions for Bolt Thread Lubrication and Torque
Settings”. Make sure, that they are fully screwed to the bottom of the threaded holes.
- Place the position cylindrical pin into the bonnet, if provided.

3.1. Assembly the balance seal, if existing.

3.1.1. Place a new balance seal over the stem on the plug, attach the packing retainer ring and fasten
them with the head stud. Tighten the studs by hands. Refer to figure “Balance seal”

Taking care not to scratch and bend the valve stem with the mounting tools!

3.1.2. Insert with care the plug unit into the inlet cage. Press it into the back seat and secure against
moving.
3.1.3. Tighten the studs using the method and pattern described in the “GENERAL
MAINTENANCE INSTRUCTIONS”, with torque specified in the Top assembly drawing.
3.1.4. Lock the studs with steel wire. Refer to the figure “Balance seal

3.2. Assembly the valve

This work required a clean work area:

- Re-check the position of the packing spacer and of the position cylindrical pin, if provided.
- Place the stem with plug perpendicularly on the soil.
- Carefully install, using two eye bolts and lifting gear, the inlet cage over the plug. Slide the
plug into the back seat and secure it against moving.
3.2.1. In case previously dismantled, insert carefully new lower packing ring to the valve seat and
lower them to the bottom of valve body recess. If lifting holes are provided, attach two eye
bolts and a sling.
3.2.2. Carefully install the inlet cage complete into the annular groove between valve body and seat.
If lifting holes are provided, attach two eye bolts and a sling.

Never rotate the inlet cage while resting on packing ring!

730/04.05 Gf Register 6-22

E06_103794-103838.doc
3.2.3. Loosen the plug clamp and lower it slowly onto the valve seat.

Never rotate the valve stem while resting on the valve seat.
Otherwise the sealing surfaces of the stem and seat may become damaged.

3.2.4. Check whether contact surfaces of bonnet and valve inside are clean, and without any
damages.
3.2.5. Install a new upper packing ring to the bonnet.
3.2.6. By means of lifting gear attached with care the bonnet, over the plug stem, to the valve body.
Observe the mark and position cylindrical pin into the bonnet, if provided,
versus the bore in the valve body!
Never rotate the bonnet while resting on packing ring!
Do not bend or damage the stem and the mating surfaces!

3.2.7. Restore the nuts / bolts connection between the bonnet and valve body. Tighten them
alternating crosswise in accordance to the “GENRAL MAINTENANCE INSTRUCTIONS”.
3.2.8. With a feeler gauge, check that the bonnet has metal-to-metal contact with the valve body. If
not, re-tighten the lower packing ring until contact is achieved. Re-check the metal-to-metal
contact between the bonnet and the valve body.
3.2.9. Restore required tightening torque of the bolts or nut connection. For the specified torque of
the bolts or nuts refer to the Top assembly drawing or the Parts list.
3.2.10. Recheck metallic tightness between bonnet and valve body with feeler gauge.

3.3. Assembly of the gland

3.3.1. Have a new packing set, the gland bush and gland flange readily available.
3.3.2. The procedure for installing and compressing of packing rings is given in: „Installation and
Retightening of GRAPHITE GARLOCK 9000 EVSP packing rings”.
For safety reasons, studs must protrude
from nuts by at least 2 threads.

3.4. Assembling the actuator unit

3.4.1. Apply lubricant to the bolted connection between yoke and valve body, according to the
“Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
3.4.2. Fit the oil drip pan, if provided.
3.4.3. Assembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 2 “Assembly the complete actuator unit”.

730/04.05 Gf Register 6-23

E06_103794-103838.doc
4 Lapping the valve seat

Dismantling the actuator unit is done according to “GENRAL MAINTENANCE

INSTRUCTIONS”, in instruction “Removing the complete actuator unit GHZ/ GHZF or
ASM”.
4.1. Disassembly the valve inserts as instructed in Section 2.2., Par. 2.2.1 to 2.2.7.
4.2. Remove the Packing set in acc. to Section 2.3.
4.3. Insert the valve stem as well as the packing spacer into the bonnet and attach this assembly
unit to a lifting gear.

Secure always the assembly unit with a lifting gear!

4.4. Apply lapping paste.

4.5. Using lifting gear, carefully insert the assembly unit on the valve stem 010 into the valve body.

Observe the position cylindrical pin, if provided, into the bonnet versus
the bore in the valve body!

4.6. At horizontal installation of valve, bolt down the bonnet at least with 3 bolts or nuts in order to
make sure of metallic contact to the valve body.
4.7. Slowly lowered the stem into the valve seat.
4.8. Repeat lapping and blue ink testing until desired result reached.
4.9. Thoroughly clean and check all parts for damage again.
4.10. Assembly is done in accordance with Section 3.

5 Electrical connections

5.1. Re-make all electrical connections.

5.2. Check that the direction of actuator movement is correct.
5.3. Check the position transmitter and re-adjust it if necessary.
5.4. Carry out a functional test.

730/04.05 Gf Register 6-24

E06_103794-103838.doc
 LP – BP STEAM ISOLATION VALVE NA 60 - 600
Instructions for Dismantling and Assembling

Relevant Drawings:
Top assembly drawing: 201335-5CH Production drawing: 103.233.018.500 Design: 200

Relevant Instructions in Register:

“General Maintenance Instructions”:
- “Revisions Intervals for CCI AG Valves”
- “Cleaning Instructions”
- “Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER
Valves”.
- “Removing the complete Actuator unit”
- “Assembly of the complete actuator unit”

In this Register:
- „Installation and Retightening of GARLOCK 9000 EVSP packing rings".

1 General Notes

Checks to be carried out before starting work:

- The valve must be depressurized, allowed to cool down to ambient temperature and drained.
- All electrical wires and cables must be de-energized.
- The piping system to pneumatic actuators must be depressurized.
- Pneumatic actuator, Instructions for Dismantling and Assembly.
During electrical operation certain parts inevitably carry lethal voltages.
To avoid personal injury and damage to the process system, disconnect the
equipment from all electric power lines.

1.1. When several valves are dismantled at the same time, care must be taken that the parts from
different valves are not mixed up.
1.2. Prior to assembly, all parts are to be cleaned and inspected for possible damage.
1.3. When assembling, use only new gaskets.
1.4. Bolted connections must be done as described in the general maintenance instructions.
The tightening torques for bolts and nuts are given in the corresponding
drawings, mounting instructions or spare parts lists. The tightening torques
applies to correctly lubricated bolts and nuts at room temperature.

730/04.05 Gf Register 6-25

E06_103794-103838.doc
 The description of the maintenance work is accompanied by illustrations of a generally
applicable nature, which show the sequence of work as clearly as possible. Since valves come
in various sizes, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to a particular valve. For further information
to a single position please consider the corresponding drawing and parts list.

2 Dismantling

Connection Actuator-Yoke-Valve horizontal.tif

Fig. 6-15 : Actuator unit

2.1. Dismantling the actuator unit

Disassembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 1 “Removing the complete actuator unit”.
Secure always the actuator unit with a lifting gear!
Pay attention the actuator unit to prevent from slipping out!
Taking care not to scratch the valve stem with the yoke!

730/04.05 Gf Register 6-26

E06_103794-103838.doc
2.2. Dismantling the valve

HBSE-NBSE_Inserts_horizontal_(103.232.177).tif

Fig. 6-16 : Valve Inserts NA 60 - 600

2.3. Expand and dismantling the stuffing box

2.3.1. Bend back the locking plates 025. Loosen and remove the nuts 024, the packing flange 014
and the gland bush 013.
2.3.2. Take the three threaded studs 023 out.
2.4. Dismantling the valve inserts

For security reasons must for handling and relocation of the individual parts,
on account of their weights, suitable tools and means of transport used.

Secure always the bonnet and all parts of the valve insert against slipping out!

2.4.1. Push slowly the stem plug assembly 010/066 against the bonnet 006 backsides and secure it
with a clamp from slipping out.
2.4.2. Stem - plug assembly 010/066, bonnet 006 and inlet cage 008 will be dismantled together.
2.4.3. Mark the position of the bonnet 006 relative to the valve body 001.
2.4.4. Check weight and center of gravity.
2.4.5. Using a hanging tool (no part of the delivery) and a suitable lifting gear see Fig. ”Example of
hanging tool”.
2.4.6. Loosen and remove the screws 017 connection between the bonnet and valve body using the
pattern described in the “GENERAL MAINTENANCE INSTRUCTIONS”.

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E06_103794-103838.doc
 CoG_NA 60-600_(103.233.018).tif

Fig. 6-17 : Example of hanging tool

2.4.7. Pull out the bonnet assembly using the forcing bolts from the valve body.
2.4.8. Remove the forcing bolts, if necessary.

Taking care not to scratch and bend the valve stem!

Observe the position cylindrical pin, if provided, into

the bonnet versus the bore in the valve body!

2.4.9. Using two threaded rods M8 for dismantling the valve seat 004, if necessary.
2.4.10. Eliminate the packing ring 035.
2.5. Separation the plug assembly 010/066, bonnet 006 and inlet cage 008
- For this work, we recommend a clean area.
2.5.1. Loosen and remove the clamp.
2.5.2. Carefully remove the bonnet from the plug assembly and the inlet cage.
2.5.3. Eliminate the packing ring 034.

Taking care not to scratch and bend the valve stem!

2.5.4. Carefully remove the inlet cage 008 from the plug assembly 010/066.

730/04.05 Gf Register 6-28

E06_103794-103838.doc
2.6. Dismantling the plug unit

Never divide the plug into his individual parts!

2.7. Dismantling the balance seal or packing ring, if existing.

Dismantle the plug assembly only

if it necessary!

Fig. 6-18 : Balance seal

2.7.1. Remove the lock wire with pliers.

2.7.2. Loosen and remove the socket head screws in accordance to the “Instructions for Bolt Thread
Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
2.7.3. Separate the Retainer ring and the balance seal packing ring from the plug
2.7.4. Thoroughly clean all parts and check them for damage.
2.7.5. Inspect the seating surfaces of the valve stem and valve seat for damage. If necessary, re-lap
the seat and plug, in case of major damage re-grind them.
2.8. Removing the Packing set
2.8.1. Remove the packing spacer, if necessary. Use a bar stock of the same diameter as the plug
stem (see Figure “Packing removal”). An air blast is usually helpful in removing all loose
material.
2.8.2. Thoroughly clean all parts and check them for damage.

Fig. 6-19 : Packing removal

Do not to damage the stuffing box!

730/04.05 Gf Register 6-29

E06_103794-103838.doc
3 Assembling

Apply lubricant to the all studs, bolts, nuts and washers as well as to threaded holes of the
valve, in accordance with the “GENRAL MAINTENANCE INSTRUCTIONS”.
DO NOT LUBRICATE THE INSERT PARTS WITH ANY GREASE!
Apply pure Graphite or Molybdenum-Disulphide powder to all surfaces
which have metal-to-metal contact.

In case previously dismantled:

- Install packing spacer and lower it to the bottom of bonnet stuffing box.
- In case of prior removal of studs and threaded studs, install them in accordance to the
General Maintenances Instructions: “Instructions for Bolt Thread Lubrication and Torque
Settings”. Make sure, that they are fully screwed to the bottom of the threaded holes.
- Place the position cylindrical pin into the bonnet, if provided.
3.1. Assembly the balance seal, if existing.
3.1.1. Place a new balance seal over the stem on the plug, attach the packing retainer ring and fasten
them with the head stud. Tighten the studs by hands. Refer to figure “Balance seal”

Taking care not to scratch and bend the valve stem with the mounting tools!

3.1.2. Insert with care the stem-plug unit 010/066 into the inlet cage 008. Press it into the back seat
and secure against moving.
3.1.3. Tighten the studs using the method and pattern described in the “GENERAL
MAINTENANCE INSTRUCTIONS”, with torque specified in the Top assembly drawing.
3.1.4. Lock the studs with steel wire. Refer to the figure “Balance seal
3.2. Mounting the plug assembly 010/066 together with the inlet cage 008 and bonnet 006

This work required a clean work area:

3.2.1. Check whether contact surfaces of plug assembly 010/066, bonnet 006 and inlet cage 008 are
clean, and without any damages.
3.2.2. Using a new packing ring 034 and carefully install the stem-plug assembly together with the
inlet cage into the bonnet.
3.2.3. Press the stem-plug assembly against the bonnet backside and secure it with a clamp between
stem and bonnet (see Fig.: “Example of hanging tool”.
Check the packing ring 034 between the inlet cage and the
bonnet is in correct position and the stem-plug assembly
have contact with the mechanical stop in the inlet cage

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3.3. Assembly the valve inserts
3.3.1. Install a new packing ring 035 to the valve body.
3.3.2. Check whether contact surfaces of bonnet, valve body and valve inside are clean, and without
any damages.
3.3.3. Turn the complete valve inserts in horizontal position
3.3.4. Assembly the bonnet 006, stem plug assembly 010/066 and the inlet cage 008 in reverse order
to para 2.5. according to Figuration “Example of hanging tool”.
3.4. Assembly the valve
3.4.1. In case previously dismantled, insert carefully a new lower packing ring 035 to the valve seat
and lower them to the bottom of valve body recess. If lifting holes are provided, attach two eye
bolts and a sling.
3.4.2. Using a hanging tool (no part of the delivery) and a suitable lifting gear see Fig. ”Example of
hanging tool”.
3.4.3. By means of lifting gear attached with care the complete valve inserts.

Observe the mark and position cylindrical pin into the

cover, if provided, versus the bore in the valve body!

3.4.4. Do not bend or damage the stem and the mating surfaces!
3.4.5. Restore the nuts / bolts connection between the bonnet and valve body. Tighten them
alternating crosswise in accordance to the “GENERAL MAINTENANCE INSTRUCTIONS”.
3.4.6. With a feeler gauge, check that the bonnet has metal-to-metal contact with the valve body.
3.4.7. Restore required tightening torque of the bolts or nut connection. For the specified torque of
the bolts or nuts refer to the Top assembly drawing or the Parts list.
3.4.8. Loosen the clamp.

Never rotate the valve stem while resting on the valve seat.
Otherwise the sealing surfaces of the stem and seat may become damaged.

3.5. Assembly of the gland

3.5.1. Have a new packing set, the gland bush and gland flange readily available.
3.5.2. The procedure for installing and compressing of packing rings is given in: „Installation and
Retightening of GARLOCK 9000 EVSP packing rings”.
For safety reasons, studs must protrude
from nuts by at least 2 threads,

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3.6. Assembling the actuator unit
3.6.1. Apply lubricant to the bolted connection between yoke and valve body, according to the
“Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG/ SULZER Valves”.
3.6.2. Fit the oil drip pan, if provided.
Assembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register “GENRAL MAINTENANCE INSTRUCTIONS”:
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 2 “Assembly the complete actuator unit”.

4 Lapping the valve seat

4.1. Disassembly the valve inserts as instructed in Section 2.3.and 2.4

4.2. Remove the Packing set in acc. to Section 2.8.
4.3. Insert the valve stem as well as the packing spacer into the bonnet and attach this assembly
unit to a lifting gear.

Secure always the assembly unit with a lifting gear!

4.4. Apply lapping paste.

4.5. Using lifting gear, carefully insert the assembly unit on the valve stem 010 into the valve body.

Observe the position cylindrical pin, if provided, into the bonnet versus
the bore in the valve body!

4.6. At horizontal installation of valve, bolt down the bonnet at least with 3 bolts or nuts in order to
make sure of metallic contact to the valve body.
4.7. Slowly lowered the stem into the valve seat.
4.8. Repeat lapping and blue ink testing until desired result reached.
4.9. Thoroughly clean and check all parts for damage again.
4.10. Assembly is done in accordance with Section 3.

5 Electrical connections

- Re-make all electrical connections.

- Check that the direction of actuator movement is correct.
- Check the position transmitter and re-adjust it if necessary.
- Carry out a functional test.

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 INSTALLATION AND RETIGHTENING OF
“GARLOCK 9000 EVSP” PACKING RINGS

Assembly
1. Be sure that the packing spacer/ bearing bush is installed and fully seated in the bottom of
the annular groove between the bonnet and the valve stem.
Do not use a pointed tool to install the packing as damage to
the sealing capability of the packing will result.
2. The GARLOCK 9000 EVSP packing is supplied from the packing vendor as a pre-
packaged 7-ring set, to be installed as shown in the Figure. The set consists of two (2)
lattice-braided end rings, two (2) high-density Graph-Lock adapter rings and three (3) low-
density Graph-Lock sealing rings.
3. Lubricate the inside diameter of the packing set with the recommended lubricant in
Table “Recommended lubricants”.
4. Install the bottom braided ring and all the Graph-Lock rings. Place each ring with the
opening 90deg to the opening on the previous ring.
5. The top-braided ring is not installed at this time. Using the packing follower or gland bush,
compress the packing far enough to enable the top-braided ring to be installed in the
packing box. Install the top braided ring.
6. Slide the packing follower or gland bush over the plug stem until it is seated on the
packing set.

7. Install the packing flange and nuts. Are three threaded bolts for tightening of the packing
installer, make sure that they are fully screwed to the bottom of the threaded holes of the
bonnet.

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 8. Torque the nuts to the recommended “optimum sealing” torque from Table “Table of
torques”. Once the “optimum sealing” torque has been applied to the packing set, it may
then be reduced to the value shown for “optimum operability” in applications where
minimum packing friction is critical, and where the system pressure allows.

RECOMMENDED LUBRICANTS
Parts Lubricant
For Packing and Seals: Dow Corning 111; Bostik NS-160

Tab. 6-2: Recommended lubricants

PACKING NUT TORQUE

FOR GARLOCK 9000 EVSP PACKING
STEM BOLT OPTIMUM OPTIMUM SYSTEM
SIZE SIZE SEALING OPERABILIT PRESSURE
(in) (mm) (in) (mm) (ft-lbs) (Nm) (ft-lbs) (Nm) (psi) (bar)
5/8 16 5/8 - 11 M 12 14 19 9 12.2 < 2500 170
16 21.6 11 14.9 < 3000 200
19 25.6 13 17.6 < 3500 250
21 28.3 21 28.4 < 4000 275
24 32.4 24 32.4 < 4500 310
1 25.40 3/4 - 10 M 16 24 32.4 16 21.6 < 2500 170
28 37.8 18 37.8 < 3000 200
32 43.2 21 43.2 < 3500 250
37 50 37 50 < 4000 275
41 55.4 41 55.4 < 4500 310
1 – 1/2 38.10 3/4 - 10 M 16 42 56.7 28 37.8 < 2500 170
50 67.5 33 44.6 < 3000 200
58 78.3 39 52.7 < 3500 250
67 90.5 67 90.5 < 4000 275
75 101 75 101 < 4500 310
2 50.80 7/8 - 9 M 20 78 105 52 70.2 < 2500 170
92 124 61 124 < 3000 200
108 145 71 145 < 3500 250
122 164 122 164 < 4000 275
138 186 138 186 < 4500 310
Tab. 6-3: Table of Packing Nut torque

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 INSPECTION AND EXCHANGE OF THE WATER INJECTING NOZZLE,
RETIGHTENING OF GRAPHITE PACKUNG RINGS

1 Important Notes

Before you open any pressure vessel, you must personally make absolutely sure
that the fluid system is completely depressurized!

This instruction is only valid for application of CCI AG original spare parts!

⇒ Avoid twisting and bending of injection nozzle piping.

When several water nozzle are dismantled at the same time, care must be
⇒ taken that the parts from different nozzles are not mixed up.
The nozzles might have been marked and must in that case be remounted in
⇒ the same position.

⇒ Cleanliness is very important when working with nozzles.

The description of the maintenance work is accompanied by perspective illustrations of a

generally applicable nature, which show the sequence of work as clearly as possible.
Since valves come in various sizes, the proportions and details of the individual components as
shown in the illustrations will not always correspond exactly to a particular valve.
For further information to a single position please consider the corresponding drawing and
parts list.

2 Disassembly of water injecting nozzles

2.1. Mark position of the water nozzles versus the valve body.
2.2. Loosen and remove the nuts, washers together with the covers.
2.3. Separate with care the injection insert from water nozzle, as shown in Figure “ Removing of
injecting insert ”.
2.4. Spray nozzle head is locked in position by means of lock washer which is bent upwards
against one of the flat sides of the nozzle head. Release the locking by bending back the lock
washer and unscrew the nozzle head, refer to Figure “Cross-section of bolted Water injecting
nozzle “.
2.5. Check the nozzle head for obstruction caused by dirt particles. Clean if required. Make sure the
water channels in nozzle head are open. Check the condition of the spring as well. If the seat
surface is damaged or the spring is worn – replace the complete nozzle head. (See Figure
“Cross-section of nozzle head “.)

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 Fig. 6-20 : Removing of injecting insert

3 Re-assembly of water injecting nozzles

The general notes to be followed.
3.1. Apply lubricant to the threads of threads the studs, the screws, the nuts and to threaded holes in
water nozzle and valve body, according to “Instructions for Bolt Thread Lubrication and
Torque Settings for CCI AG/ SULZER Valves”.
3.2. Be sure that the bolted water nozzle is on place, observing the mark “water nozzle – valve
body” and the screw connecting is correctly installed,. Re-check the screws torque.
3.3. It must be ensured that the studs are completely screwed into the water nozzle. Retighten if
necessary.
3.4. Assembly the nozzle head and nozzle holder and secure the nozzle head with lock washer as
previously.
3.5. Measure and record the packing height of all packing rings.
3.6. Assembly the injection insert. Slide the spacer bush, if provided and all new packing rings
with care onto the nozzle holder in accordance to the corresponding drawing.
3.7. Insert carefully the injecting insert into the water nozzle. Make sure that the lower packing ring
is properly fitted.
3.8. Install the cover and the washers, screw in the nuts and tighten them evenly diagonally be hand
so that the cover rests firmly on the two upper packing rings.
3.9. Measure and record the distance “x”, refer to the Figure “Cross-Section of bolted of welded
Water injection nozzle”.
3.10. Tighten the nuts crosswise with a wrench. The packing rings are to be compressed by a length
equal to 8% of the uncompressed packing height.

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3.11. Tighten the nuts until distance “x” – 8% (uncompressed packing height) = “x” - 2.5 mm is
reached.
3.12. Studs must protrude from nuts by least 2 threads, after the packing rings have been
compressed.
After installing or exchanging the packing rings, they must be checked for
tightness after the valve has been commissioned.
If not tight, they must be re-tightened according to the following instructions.

4 Re-tightening of GRAPHITE packing rings

In case packing leaks despite having been tightened as specified, or if leakage has developed
due to operational wear, packing must be re-tightened in a step by step procedure as follows:
9. Retighten packing by 0.4 %* relative to uncompressed packing height
10. Wait 3 minutes
11. Check for leakage
12. Repeat above procedure, if necessary.
If no further leakage is observed, tighten packing once more by another 0.4 %*.
Total re-tightening must not exceed 2 %* of uncompressed packing height.

Packing must be tightened only as far as necessary. Excessive tightening causes

undue! Friction of valve stem without improving tightness.

If tightness of gland cannot be attained by further tightening, all packing rings must be
replaced.

Fig. 6-21 : Cross-section of nozzle head

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 Fig. 6-22 : Cross-section of bolted Water injecting nozzle

Fig. 6-23 : Cross-section of welded Water injecting nozzle

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 FAULT-FINDING AND RECOMMENDED REPAIR
FOR VALVES AND ACTUATORS

If assembly and maintenance procedures on CCI AG control valves and hydraulic actuators are
observed as described in operating manual, no problems will occur during operation.
The following table below identifies potential problems, possible causes and recommended
repairs.
Tab. 6-4: Fault-finding and recommended repair

Problem Possible Cause Recommended Repair

Gland Packing Packing incorrectly 1 Compress packing acc. to operating manual
Leakage compressed
Packing damaged or 2 Replace packing acc. to operating manual
incorrectly installed
Valve stem scratched 3 Disassemble valve and inspect stem, replace
stem if needed. Reassemble valve with new
packings
Cover Gasket Cover bolts incorrectly 4 Tighten cover bolts acc. to specification
Leakage tightened
Cover gasket damaged 5 Replace cover gasket
Valve Seat Stem is not enough 6 Existing system pressure in actuator too low
Leakage pressed against seat by
actuator
Incorrect calibration of 7 Check closing signal of positioner
positioner loop
Damage to seat 8 Disassemble valve and rework seat sealing
surfaces
Valve Stroke Malfunction of actuator 9 Check control unit and system pressure
does not follow
Incorrect calibration of 10 Check positioner loop
Input Signal
positioner loop
Stem is hard to move 11 Disassemble valve and make stem easy
moving
Actuator Damaged seals 12 Replace corresponding seals
Leakage
Bolted connections 13 Tighten or replace bolted connections
loose or damaged respectively

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 FIGURES CONTENTS REGISTER 6
FIG. 6-1 : EXPLODED VIEW GHZ/ GHZF ACTUATORS 4
FIG. 6-2 : PISTON ROD GASKET, DESIGN FOR „ MINERAL OIL“ 5
FIG. 6-3 : PISTON ROD GASKET, DESIGN FOR „ PHOSPHATE ESTER FLUID “ 5
FIG. 6-4 : FITTING OF THE INDIVIDUAL PISTON SEAL COMPONENTS 8
FIG. 6-5 : ACTUATOR UNIT 10
FIG. 6-6 : VALVE INSERTS HBSE 280 - 250 11
FIG. 6-7 : PACKING REMOVAL 12
FIG. 6-8 : LIFTING ARRANGEMENT OF VALVE INSERT 13
FIG. 6-9 : BALANCE SEAL 13
FIG. 6-10 : ACTUATOR UNIT 18
FIG. 6-11 : VALVE INSERTS NBSE 60 – 400 - 2 19
FIG. 6-12 : PACKING REMOVAL 20
FIG. 6-13 : LIFTING ARRANGEMENT OF VALVE INSERT 21
FIG. 6-14 : BALANCE SEAL 21
FIG. 6-15 : ACTUATOR UNIT 26
FIG. 6-16 : VALVE INSERTS NA 60 - 600 27
FIG. 6-17 : EXAMPLE OF HANGING TOOL 28
FIG. 6-18 : BALANCE SEAL 29
FIG. 6-19 : PACKING REMOVAL 29
FIG. 6-20 : REMOVING OF INJECTING INSERT 36
FIG. 6-21 : CROSS-SECTION OF NOZZLE HEAD 37
FIG. 6-22 : CROSS-SECTION OF BOLTED WATER INJECTING NOZZLE 38
FIG. 6-23 : CROSS-SECTION OF WELDED WATER INJECTING NOZZLE 38

TABLE CONTENTS REGISTER 6

TAB. 6-1: RECOMMENDED TORQUE VALUES OF THE SCREWS 7
TAB. 6-2: RECOMMENDED LUBRICANTS 34
TAB. 6-3: TABLE OF PACKING NUT TORQUE 34
TAB. 6-4: FAULT-FINDING AND RECOMMENDED REPAIR 39

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 REGISTER 7
DISMANTLING & ASSEMBLY
SPRAY-WATER CONTROL VALVES
Contents

Register 7.1: Dismantling & Assembly

- HP – Spray-water Control Valve 100DSV 5x5 201335-2CH

Register 7.2: Installation and Maintenance Instructions

- HP – Spray-water Isolation Valve 840G 5x5 Globe 201335-3CH
LP – Spray-water Control Valve 840H 5x5 Globe 201335-6CH
LP – Spray-water Isolation Valve 840G 5x5 Globe 201335-7CH

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