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OPERATION & MAINTENANCE MANUAL

MODEL APH HYDRAULIC ACTUATOR

TABLE OF CONTENTS
I.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

II.

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

III.

Actuator Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

IV.

Actuator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V.

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

VI.

Gate Valve Sizing Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

VII.

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VIII.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

IX.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

X.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

XI.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

XII.

Actuator Valve Sizing Chart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

XIII.

Actuator/Bonnet Assembly Drawing & Bill of Material . . . . . . . . . . . . . . . . . . . . . 14

XIV.

Sub-Assembly Operations

Piston Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Top Shaft Packing Retainer & Cylinder Assembly/ Assembly Drawing . . . . . . . . . . . . 16

XV.

Bonnet Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

XVI.

Bonnet to Gate Valve Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . 18

XVII.

Main Actuator Bonnet and Gate Valve Assembly/ Assembly Drawing . . . . . . . . . . . . . 19

XVIII. Setting the Gate Valve Drift/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . 21


Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

XIX.

Field Removal and Replacement of Actuator Seal & Top Cylinder Seal . . . . . . . . . . . . 23

XX.

Field Removal and Replacement of Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . 24

XXI.

Field Removal and Replacement of Top Shaft Packing Retainer Seal . . . . . . . . . . . . . 25

XXII.

Field Removal and Replacement of Bonnet Seal Packing . . . . . . . . . . . . . . . . . . . . 26

XXIII. Burst Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


XXIV. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
XXVI. Testing and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
XXV.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

XXVI. Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

page 2

INTRODUCTION
The Array model APH is a Hydraulic Actuator. This actuator is designed as a fail closed operator. The SSV APH
Hydraulic Actuator should be installed on the second valve and flow wing valve in the wellhead flow stream.
When two master valves are used, the SSV should be the top master valve. The SSV will be tested in accordance
with procedures given in the American Petroleum Institute specification 6A, latest revision. SSVs located in
federal waters should only be serviced by technicians that meet qualifications as defined by the Minerals
Management Service (MMS).
This installation and maintenance manual gives factory required assembly, disassembly and installation
procedures, trouble shooting and technical specifications.
Typical uses are for critical valve applications on wellhead production, drilling and exploration and pipelines.

ACTUATOR OPERATION
Array model APH Hydraulic Actuators are designed to operate Array Fail-Safe Bonnet Assemblies used on gate
valves and move them from their Fail-Safe positions. The thrust required to do this is created by application of
adequate control pressure to the actuator inlet port. Hydraulic pressure acting on the piston overcomes the
thrust created by the forces of the valve pressure acting on the bonnet stem and gate friction due to any pressure
differential acting on the valve gate and dual set of springs. It will open fail-closed gate valves. Removal of this
control pressure allows the bonnet stem forces to return the valve gate to its fail-safe position. The actuator
return spring provides the required force to overcome dynamic seal friction and the weight of moving parts
when no pressure exists in the valve.
When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft
will depend upon whether the valve is fail-closed and how much pressure differential is present across the
valve gate. Fail-closed valves will initially open with a sudden jerk as the gate cracks open and the pressure
differential is reduced. This is normal and does not damage the valve or hinder its function. The severity and
travel of this rapid motion depends on the amount of pressure differential across the valve gate. The greater the
differential, the more rapid the motion for a longer amount of the total valve stroke. The remainder of the
actuator motion should be smooth and uniform.
Upon removal of control pressure from actuators mounted on fail-closed valves, the motion should be smooth
throughout the entire stroke. Speed of this action depends on many factors such as how fast a differential
builds across the gate, is a locally mounted valve being used to exhaust the control pressure and the size of the
actuator and valve. As a general rule, the faster the control pressure is removed from the actuator the quicker
it will close.
The combination of compression spring assembly will provide approximately 1,750 to 2,000 pounds of force in
the closed position of the gate valve.

page 3

ACTUATOR TECHNICAL SPECIFICATION

1.

Applicable Gate Valve Bore

113/16" thru 71/16"

2.

Applicable Gate Valve W.P.

2M thru 15M

3.

Trim (API 6A material Class)

BB

4.

Product Specification Level (PSL)

5.

Performance Rating

PR-2

6.

Temperature Classification

P -20 to 180F (-29C to -82 C)

7.

Maximum Operating Pressure

5,000 psi (345 Bars)

8.

Maximum Test Pressure

7,500 psi (518 Bars)

9.

Pressure Relief (Burst Disc) Setting (Stainless)

5,000 psi @ 130 F (345 Bars @ 54 C)

10.

Actuator Volume

See chart on page 5

11.

Weight

See chart on page 5

12.

Dimensions

See chart on page 5

page 4

ACTUATOR DIMENSIONS
page 5

MODEL

APH 025 x 020

in
3

C
mm

18.00 457

in

mm

in

mm

10.36

263

5.40

137

in mm

in

2.00 50

mm

2.75 69

APH 035 x 020

23.78 604

15.50

393

7.40

187

2.50 63

2.75 69

APH 035 x 030

24.78 629

15.50

393

7.40

187

2.50 63

2.75 69

APH 045 x 020

29.50 749

21.14

536.

10.12 257

2.50 63

2.75 69

APH 045 x 030

30.50 774

21.14

536

10.12 257

2.50 63

2.75 69

APH 045 x 040

31.50 800

21.14

536

10.12 257

2.50 63

2.75 69

APH 045 x 050

32.50 825

21.14

536

10.12 257

2.50 63

2.75 69

APH 045 x 060

33.50 850

21.14

536

10.12 257

2.50 63

2.75 69

APH 065 x 040

37.65 956

27.10

688

12.96 329

2.75 69

2.75 69

APH 065 x 050

38.65 981

27.10

688

12.96 329

2.75 69

2.75 69

APH 065 x 060

39.65 1007

27.10

688

12.96 329

2.75 69

2.75 69

APH 065 x 070

40.65 1032

27.10

688

12.96 329

2.75 69

2.75 69

B
C

All Upper Housing


Threads are
8 UN-2A
A

MODEL

SWEPT VOLUME

CLOSING TIMES

WEIGHT

in3

cm3

seconds

lbs

kgs

APH 025 x 020

9.5

156

24

46

21

APH 025 x 020

11.0

180

35

46

21

APH 035 x 020

19.0

311

24

112

51

APH 035 x 020

22.0

361

35

112

51

APH 035 x 030

26.0

426

46

117

53

APH 035 x 030

31.0

508

57

117

53

APH 035 x 040

39.0

639

79

129

59

APH 045 x 020

34.0

557

13

279

127

APH 045 x 020

40.0

587

35

279

127

APH 045 x 030

46.0

675

46

284

129

APH 045 x 030

54.0

793

57

284

129

APH 045 x 040

69.0

1013

79

285

130

APH 045 x 050

84.0

1233

911

276

125

APH 045 x 060

98.0

1439

1012

281

128

APH 065 x 040

150.0 2459

79

549

249

APH 065 x 050

186.0 3049

911

552

251

APH 065 x 060

218.0 3573

1012

560

254

APH 065 x 070

253.0 4147

1113

562

255

ORDERING INFORMATION
The following information should be provided when requesting a quote or issuing a purchase order
to Array Products for an APH Actuator.

Actuator
Model of Actuator:_______________________________________________________________________________
Size of Actuator: ________________________________________________________________________________
Actuator Control Pressure Availability: ______________________________________________________________
Special Requirements:
Testing _______________________________________________________________________________________
Coating_______________________________________________________________________________________
Non-Rising Top Shaft ___________________________________________________________________________
Certification / Specification_______________________________________________________________________

Bonnet / Gate Valve


Gate Valve Bore Size:_____________________________________________________________________________
Rated Working Pressure of Gate Valve:______________________________________________________________
Temperature Rating: _____________________________________________________________________________
Material Class: _________________________________________________________________________________
PSL Rating:_____________________________________________________________________________________
PR Rating:______________________________________________________________________________________
Interface Drawing Availability:______________________________________________________________________

Accessories
Fusible Lock Open Cap: __________________________________________________________________________
Fusible Manual Override: _________________________________________________________________________
Hydraulic Override: ______________________________________________________________________________
Stem Protector (Clear) (Metal):_____________________________________________________________________
Electronic Switches Proximity: ____________________________________________________________________

page 6

CONTROL PRESSURE EQUATIONS


page 7

VALVE WORKING PRESSURE


VALVE

BORE SIZE

3,000 PSI

5,000 PSI

10,000 PSI

15,000 PSI










11316

















APH 25 x 020
4329 psi
.418 x wp + 149 psi
APH 035 x 020
2109 psi
.205 x wp + 59 psi
APH 045 x 020
1279 psi
.116 x wp + 119 psi

APH 035 x 020


3134 psi
.205 x wp + 59 psi
APH 045 x 020
1859 psi
.116 x wp + 119 psi



APH 025 x 020
APH 025 x 020


1334 psi
2124 psi

2116
.395 x wp + 149 psi
.395 x wp + 149 psi








APH 035 x 020


2329 psi
.227 x wp + 59 psi
APH 045 x 020
1419 psi
.130 x wp + 119 psi

APH 035 x 020


3464 psi
.227 x wp + 59 psi
APH 045 x 020
2069 psi
.130 x wp + 119 psi






2916




APH 025 x 020


1757 psi
.536 x wp + 149 psi
APH 035 x 030
851 psi
.264 x wp + 59 psi

APH 025 x 020


2829 psi
.536 x wp + 149 psi
APH 035 x 030
1379 psi
.264 x wp + 59 psi

APH 035 x 030


2699 psi
.264 x wp + 59 psi
APH 045 x 030
1629 psi
.151 x wp + 119 psi

APH 035 x 030


4019 psi
.264 x wp + 59 psi
APH 045 x 030
2384 psi
.151 x wp + 119 psi






318

3116


APH 035 x 030


1193 psi
.378 x wp + 59 psi
APH 045 x 030
767 psi
.216 x wp + 119 psi

APH 035 x 030


1949 psi
.378 x wp + 59 psi
APH 045 x 030
1199 psi
.216 x wp + 119 psi

APH 045 x 030


3839 psi
.378 x wp + 59 psi
APH 045 x 030
2249 psi
.213 x wp + 119 psi

APH 045 x 030


3314 psi
.213 x wp + 119 psi






4116




APH 035 x 040


1751 psi
.564 x wp + 59 psi
APH 045 x 040
1085 psi
.322 x wp + 119 psi

APH 035 x 040


2879 psi
.564 x wp + 59 psi
APH 045 x 040
1729 psi
.322 x wp + 119 psi

APH 045 x 040


3339 psi
.322 x wp + 119 psi
APH 065 x 040
1543 psi
.148 x wp + 63 psi

APH 045 x 040


4949 psi
.322 x wp + 119 psi
APH 065 x 040
2283 psi
.148 x wp + 63 psi






518




APH 045 x 050


1682 psi
.521 x wp + 119 psi
APH 065 x 050
780 psi
.239 x wp + 63 psi

APH 045 x 050


2724 psi
.521 x wp + 119 psi
APH 065 x 050
1258 psi
239 x wp + 63 psi

APH 045 x 050


5329 psi
.521 x wp + 119 psi
APH 065 x 050
2453 psi
.239 x wp + 63 psi

APH 065 x 050


3648 psi
.239 x wp + 63 psi






638




APH 045 x 060


2429 psi
.770 x wp + 119 psi
APH 065 x 060
1230 psi
.389 x wp + 63 psi

APH 045 x 060


APH 065 x 060
3939 psi
3953 psi
.770 x wp + 119 psi
.389 x wp + 63 psi
APH 065 x 060

2008 psi
.389 x wp + 63 psi

APH 065 x 060


5898 psi
.389 x wp + 63 psi




7116

APH 065 x 070


1348 psi
.428 x wp + 63 psi

APH 065 x 070


2203 psi
.428 x wp + 63 psi

APH 065 x 070



4343 psi
.428 x wp + 63 psi

Note: The designed values provided above only apply to actuators manufactured for Array gate valves and are provided for reference only. (SEE NOTES ON NEXT PAGE)

CONTROL PRESSURE EQUATIONS


page 8

NOTE:
All actuator sizing complies with API 6A 10.16.3.7 (latest edition) force output valve requirements.
PSI is required pressure to crack valve @ maximum working pressure.
Sizing equation includes spring load.
PSI number is total of equation and spring load to open gate valve @ maximum working pressure.
Control pressure equation x valve working pressure + total spring load. When calculating control supply
for the APD use this equation.

ACTUATOR SELECTION PROCEDURE


Determine gate valve specifications such as size, maximum rated working pressure,
projected shut-in pressure and maximum flow line pressure.

DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY


Determine maximum flow line pressure in gate valve.
What is the available hydraulic pressure supply at site?
Multiply the maximum flow line pressure by the matrix equation and add the remaining number of psi for
the total hydraulic pressure to be used to open gate valve.

APH SIZING CHART


page 9

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ACTUATOR VALVE SIZING CHART PROCEDURE


page 13

1. To select the proper actuator size and control pressure you must first determine the
gate valve bore size and the maximum working pressure of the valve.
2. Now determine the maximum flowing and shut in pressure for production.
3. Determine the available hydraulic control supply pressure at location.
4. Using the appropriate gate valve bore chart, find the y-axis location and draw a vertical line to the top of the chart.

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5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point defines the minimum
required actuator control pressure to open the gate valve.

Example: A valve pressure of 8,400 psi requires an actuator hydraulic control pressure of 2,824 psi to open gate valve
(APH 045 x 040). See control pressure equation on pages 7 & 8.

PARTS LIST
page 14
#

DESCRIPTION

Top Shaft

Piston

Polypak Seal (AK)

Wear Bearing (AK)

Top Shaft Retainer Plate

Socket Head Cap Screw

Top Shaft Packing Retainer

Wiper Ring (AK)

Wear Bearing (AK)

10

Polypak Seal (AK)

11

Retainer Ring (AK)

12

Cylinder

13

Housing Lock Ring

14

Housing Shear Ring

15

Bolt

16

Spring Adjusting Nut

17

Stem Nut

18

Upper Spring Plate

19

Spring Guide Tube

20

Lower Spring Plate

21

Inner Spring

22

Housing

23

Socket Head Set Screw

24

Bonnet Ring

25

Burst Disc

26

Caution Tag (NS)

27

Nameplate (NS)

28

Drive Screw (NS)

29

Washers

8
11
7
5
9
3
10
2
25
4
6
12

18

19
20

30

32

Bonnet Stem

31

Drift Shims

32

Packing Retainer

33

O-Ring (BK)

34

O-Ring (BK)

35

Polypak Seal (BK)

36

Bonnet

37

Test Fitting

38

Nameplate (NS)

39

Drive Screws (NS)

14
16

17

23
21
22

24

BONNET
30

13

31
33

34

14
13

35

29

15
36

(NS) = Not Shown


(AK) = Actuator Redress Kit Items
(BK) = Bonnet Redress Kit Items

Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves manufactured by companies other than
Array Products. In those cases the specific differences are usually limited to the design of the bottom of the bonnet and operating stem.

37

SUB ASSEMBLY OPERATIONS


The following procedure outlines the assembly of the actuator. The sub assemblies will be combined into the
main assembly.
It is important that the assembly area be clean and free of all dirt particles and any other solid that could impede
proper assembly cleanliness.

PISTON SUB ASSEMBLY


1. Inspect (Piston #2) one each, for dings, nicks or scratches.
Clean thoroughly, inspect sealing surfaces.
2. Lightly cover entire piston with high grade lubricant and set aside.
3. Inspect (Top Shaft Retainer Plate #5) one each, verify that holes
and surfaces are clean and free of debris. Lightly grease.
4. Examine (Top Shaft #1) one each, verify finish on seal surface.
Lightly grease.
5. The (Socket Head Cap Screw #6) four each, and (Wear Bearing #4)
one each, conclude the piston assembly.
6. Check (Polypak Seal #3) for marks and cuts. Inspect energizer
o-ring for surface imperfections. Check the sealing edges (O.D./I.D.)
carefully by moving fingertips over the surfaces.
7. Place piston on flat clean surface with tapped holes facing upward.
Grease sealing diameter and shoulder. Place Polypak over piston
groove and push down gently. The Polypak o-ring should be facing
upwards. Seat firmly on shoulder.
8. Install top shaft base vertically into counter bore of piston. Seat
firmly by hand. Set top shaft retainer plate over and down onto top
of piston. Align four holes on the top shaft retainer plate to the four
tapped holes in the piston. Apply neverseez lightly to threads.
Install all (Socket Head Cap Screws #6). Tighten in clockwise
direction. Apply 25 to 30 ft. lbs of torque each.
9. Wipe wear bearing surface clean and install (Wear Bearing #4).
The bearing must fit snug with no overlap. The bearing is skive cut
and must fit with little or no gap.
10. The piston assembly in now complete. Set aside.

page 15

TOP SHAFT PACKING RETAINER SUB ASSEMBLY


1. Inspect (Top Shaft Packing Retainer #7) threads and sealing surface. Check for broken or torn threads. Be sure that
bore is smooth and bearing groove is clean of debris.
2. Install (Rod Wiper #8) into top groove of top shaft packing retainer. Inspect rod wiper for tears. Do not grease.
3. Install (Wear Bearing #9) into internal groove of top shaft packing retainer. Make sure bearing is seated into groove
properly. No overlap is permitted. The top shaft will not move freely through top shaft packing retainer if bearing is
not properly seated.
4. Set top shaft packing retainer aside.

CYLINDER SUB ASSEMBLY


1. Inspect all Surfaces on (Cylinder #12) threads for tears and burrs.
Inspect bore with hand for ripples, tears, high spots and surface
finish. Check top bore for thread tears and surface finish. Check lead
in angle at large opening for smooth entry. Inspect two 1/2 NPT tapped
holes for tears or burrs. Clean entire cylinder and grease lightly.
2. Place cylinder in a vertical position with O.D. threads at top.
3. Install (Wear Bearing #9) into bore of (Top Shaft Packing Retainer
#7). Clean bore prior to installation. Wear bearing must fold cleanly
into bore with no overlap. Skive cut must be clean.
4. G
 rease top sealing bore generously. Insert (Polypak #10) with
o-ring energizer facing downward. Polypak will stop on shoulder.
5. A
 pply neverseez to threads on (Top Shaft Packing Retainer #7).
Insert part into top threaded bore of cylinder. Rotate part in a
clockwise direction to a positive stop. Using a wrench, torque the top
shaft packing retainer firmly.
6. Install (Retainer Ring #11) into groove located at top of cylinder
threaded boss.
7. Grease (Cylinder #12) generously.
8. Place piston sub assembly on a flat planer surface. Lift cylinder
sub-assembly up.
9. A
 lign top shaft on piston with bore of cylinder, lower cylinder down
and over piston. The piston should enter the cylinder bore smoothly.
After the piston has entered bore of cylinder rotate cylinder and
piston assembly to the horizontal position. Continue pushing the
piston by hand into the bore of the cylinder until top shaft has
extended through the top shaft packing retainer. At this point,
thread lifting eye into top shaft. Lift the entire assembly and set
aside. The weight of the assembly will force the piston to travel
further into the cylinder bore until reaching a positive stop.

page 16

page 17

ARRAY BONNET ASSEMBLY


The bonnet is part of the actuator that connects the actuator to the valve. The following outlines the assembly of the
Array Bonnet Assembly. All item numbers correspond to Bill of Material items.
CAUTION: It is imperative that when assembling the Bonnet, the assembly area be clean and free of all flying debris.

PROCEDURE
1. Examine the (Packing Retainer #32). Verify that bore threads are
clean and in good condition and o-ring grooves are clean and in
good condition.
2. Thoroughly clean the (Packing Retainer #32), removing all foreign
debris from thethreads and o-ring grooves.
3. Thoroughly lubricate the entire part with assembly lubricant and
then set aside.
4. Examine the (Bonnet #36). Verify that bore and threads are clean
and in good condition.
5. Thoroughly clean the Bonnet bore and O.D. threads and lightly
lubricate packing box with assembly lubricant.
6. Install the (Polypak Seal #35) in the bonnet packing box with the
packing o-ring energizer facing down. Push the packing rings down
to a positive stop.
7. Pick up the Packing Retainer and carefully thread the retainer into
the Bonnet with clockwise rotation to a positive stop. Tighten
retainer securely with a pipe wrench. Remove any metal shavings or
bits of residue from wrench operation.
8. Install a 1/2" (Test Fitting #37) in the tapped hole in the Bonnet
flange and tighten fitting securely. Use pipe tape or liquid (Teflon).
9. E
 xamine the (Bonnet Stem #30). Verify that threads are clean and
in good condition, seal surface is clean and free of nicks, dings,
burrs and scratches.
10. Lightly lubricate the entire seal surface of the stem with
assembly lubricant.
11. Pick up the Bonnet and place it on its side.
12. Pick up the Stem and pass the Stem through the Bonnet and
packing set, from the flange side of the Bonnet until the Stem
backseat contacts its stop point. CAUTION: Be careful not to nick
I.D. sealing surface of packing by nose of bonnet stem.
Note: The design of the Stem/Gate connection will vary depending
on size, working pressure and manufacturer.

page 18

ARRAY BONNET TO GATE VALVE ASSEMBLY


The Array Products Bonnet Assembly when installed on an unbalanced valve is the interface between the Actuator and
the gate valve. The Bonnet will provide leak free sealing. Before adapting the actuator the bonnet stem should be
stroked freely by hand in both directions. When the valve is pressured in the full closed position the stem will be urged
outward because of the valve pressure acting on the bonnet stem diameter. The Array Products bonnet is used as an up
and down stop for the valve. This design prevents damage to the valve bonnet stem in the event of accidental over
pressuring of the actuator. The bonnet provides positive stroke reliability by use of spacers (provided with the actuator).
Once proper stroke has been set, a constant stroke distance will be maintained though the normal service life. All Array
bonnet assemblies are shipped ready for installation on the valve.
WARNING: During installation pay special attention to removal of any devices on the valve such as stem balancing
components, internal gate down stop devices and any adjustments to gate travel.

PROCEDURE
1. Push the (Bonnet Stem #30) down out of the (Bonnet #36) until the
stem end for gate adaptation is exposed.
2. Thread the gate onto the exposed portion of the stem in a closing
direction. Positiongate as required by valve manufacturers
installation procedure.
3. Rotate the gate slightly in either direction to align the slot in the
stem with the mating hole in the gate lift nut. Drive the pin
(supplied by the valve) through the gate pin hole in the stem slot.
4. Install new bonnet seal ring (supplied with the valve) in the valve
body and then carefully lower the gate into the valve body, between
the seats and allow the bonnet to pass over the valve body stud.
5. Install the valve body nuts on the studs and make up connection as
required by valve manufacturer.
6. The (Bonnet Stem #30) should slide easily upwards by pulling
the gate up to the fully closed position with your hands. The
(Stem Nut #17) can be threaded onto the stem for better leverage.
Do not use any other device or tool to lift the (Bonnet Stem #30)
to the fully closed position other than previously mentioned.

page 19

MAIN ASSEMBLY ACTUATOR ASSEMBLY TO BONNET AND GATE VALVE


1. The Bonnet Assembly is installed on a reverse acting gate valve. (See bonnet to gate valve assembly) and the drift
properly set with the correct amount of shims. (See setting the valve drift section).
2. With bonnet and valve assembly in the vertical position, install (Stem Nut #17). Rotate in a clockwise direction to a
positive stop. Using wrench, tighten firmly.
3. Install two (Socket Head Set Screws #23). Use neverseez sparingly. Tighten both screws securely. Caution: inspect
both screw engagement into stem nut. No protrusion of either screw is permitted as this will interfere with
assembly ofspring adjusting nut.
4. Place (Housing Lock Ring #13) and housing (Housing Shear Ring #14) down onto flange of bonnet. They should
remain loose. They will be used upon addition of (Housing #22).
5. Place (Bonnet Ring #24) onto threaded nose of bonnet. Apply neverseez to I.D. threads on bonnet ring. Rotate the
bonnet ring counterclockwise to locate the thread start and then clockwise to a positive stop. Grease top portion of
bonnet ring generously. The springs will rotate when being compressed. Tighten bonnet ring securely, lock threads.
6. Place the (Inner Spring #21) down onto face of bonnet ring.
7. Place the (Upper Spring Plate #18) down on top of the inner and outer spring set. Align the ring of the plate to match
the O.D. and I.D. of the spring set.
8. Install the (Spring Guide Tube #19) into the bore of the upper spring plate. The tube shoulder will nest inside of the
spring plate.
9. Place the (Lower Spring Plate #20) into the bore of the spring guide tube until the lower spring plate shoulder stops
on the inner shoulder of the spring tube.
10. Thread the (Spring Adjusting Nut #16) onto the (Stem Nut #17) O.D. threads in a clockwise rotation. An adjustable
long wrench will be required. Rotate to a positive stop. The two springs are fully loaded at this point. Note: the
springs may rotate when being compressed. This action is normal and presents no cause for alarm.
11. Lift the housing carefully over the assembled bonnet and spring cartridge. The (Housing #22) will stop on the
shoulder of the (Bonnet Ring #24) on bonnet end.
12. Insert the (Housing Shear Ring #14) into the groove in the housing. CAUTION: Make sure ring is seated and sprung
outward on bonnet end. (Must fit tight in groove).
13. Insert (Housing Lock Ring #13) into groove inside of housing shear ring on the bonnet end. Note: if for any reason,
the lock ring does not install easily or is cocked in the groove, remove and reseat shear ring, then reinstall lock ring.
14. Install four (Washers #29) and (Bolts #15) into four tapped holes in bottom of bonnet ring. Apply neverseez lightly
to threads . Wrench torque firmly.
15. Using lifting eye installed in top shaft, lift cylinder and piston assembly into bore of (Housing #22).
CAUTION: be careful when lowering assembly for proper alignment. The cylinder and piston assembly will stop
on (Housing #22) shoulder. Remove lifting eye from top shaft.
16. Insert the (Housing Shear Ring #14) into the groove in the (Housing #22). CAUTION: Make sure ring is seated and

page 20

spring outward. (Must fit tight into groove).


17. Insert (Housing Lock Ring #13) into groove inside of (Shear Ring #14). Note: if for any reason the lock ring does not
install easily or is cocked in the groove remove and reseat shear ring, then reinstall lock ring.
18. Install four (Washers #29) and (Bolts #15) into four tapped holes in top of (Cylinder #12). Apply neverseez lightly
to threads. Using wrench torque firmly.
19. Install a solid 1/2 NPT plug in one of the tapped holes located at the top of the (Cylinder #12). The solid plug should
be sealed with Teflon tape or Teflon liquid sealant. Plug to remain during testing.
20. Apply (Caution Tag #26) to O.D. of cylinder. Must be in close proximity to safety relief device. (Not Shown)
21. Actuator testing can now begin. Consult section of actuator testing.

page 21

SETTING THE GATE VALVE DRIFT


1. Setting the drift can only be accomplished after the bonnet assembly has been installed on the gate valve. All studs
and bolts have been torqued with all stem to gate connections completed.
2. With the gate valve in the vertical position, place four (Drift Shims #31) on top of the packing retainer.
3. Thread the (Stem Nut #17) onto the bonnet stem to a dead stop.
4. Using both hands, push down on the stem nut to bottom out on top of the shims.
5. Check the drift alignment by running the appropriate size drift tool through the bore. If the gate is not aligned with
the valve bore, pull up on the stem to the fully closed position and remove the down stop and add or subtract shims
as required to properly align the gate with the gate valve bore. (See Illustration)
6. The stroke length is now set permanent.

page 22

GATE
GATE

ADD SHIMS

REMOVE SHIMS

FIELD REMOVAL AND REPLACEMENT OF ACTUATOR SEAL


This procedure can be performed with the actuator installed on the bonnet and gate valve. The actuator can be
mounted in the horizontal or vertical position. The large coil springs and housing does not need to be removed.
The gate valve does need to be in the fully closed position with the top shaft fully extended. This fully closed position
of the reverse acting gate valve position the bonnet stem in the back seated fire safe mode.
Tools required for field disassembly are adjustable wrench large and small; large and small blade screwdrivers;
set of allen wrenches, o-ring extraction tool; safety glasses; hard hat and safety boots.

PROCEDURE
The following procedures should be followed in all cases of disassembling a production hydraulic actuator.
When replacing the actuator seals (2 each) from the cylinder follow these directions carefully.
1. Disconnect power source going to Actuator inlet. Be careful not to spill hydraulic fluid.
2. Do not disconnect the pressure relief device.
3. If a high pressure quick exhaust valve is used, disconnect from Actuator and set aside.
4. If electronic proximity switches are installed remove from top of cylinder. Do not injure or mishandle. Set aside.
5. If other accessories are mounted to the top of the Actuator remove and set aside. These accessories can be clear
stem protector, fusible manual override and fusible lock open cap. CAUTION: If a fusible lock open cap is installed
on the Actuator. Prior to any disassembly pressurize actuator to full open position to release upward thrust load
on cap. This operation will prevent injury to personnel and equipment. After pressurizing actuator unscrew
fusible cap and set aside.

REPLACE TOP CYLINDER SEAL


6. Remove (Retainer Ring #11) from (Cylinder #12) threaded boss.
7. Using an adjustable wrench rotate (Top Shaft Packing Retainer #7) in a counter-clockwise direction.
CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is
noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged.
CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING.

page 23

FIELD REMOVAL AND REPLACEMENT OF ACTUATOR PISTON SEAL


1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle.
Set aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION. If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
6. Remove 4 each (Bolts #15) and (Washers #29) from top of APH Actuator. Set aside.
7. Remove (Housing Lock Ring #13) and set aside.
8. Using a thin blade screwdriver, remove (Housing Shear Ring #14) Note: Debris may have hidden milled removal
slots on ring. If possible clean surface prior to removal.
9. (Housing Shear Ring #14) should be removed easily. If for any reason the ring is difficult to remove, stop and check
pressure attachment to (Cylinder #12) and check for trapped internal pressure.
10. Install 3/4-10UNC-2A lifting eye into (Top Shaft #1) Thread complete.
11. A
 fter removal of (Housing Shear Ring #14) lift (Cylinder #12) from Actuator (Housing #22) using lifting eye.
Set assembly on flat surface.
12. Clean entire outside surface of (Cylinder #12) assembly.
13. Place (Cylinder #12) assembly on a horizontal position and remove lifting eye from (Top Shaft #1) Hold
(Cylinder #12) assembly firmly. Push (Top Shaft #1) and (Piston #2) assembly out of cylinder bore. Be careful
not to mishandle piston assembly as hydraulic fluid will be present and slippery. Clean piston assembly.
Remove piston (Polypak Seal #10), inspect seal. Report any unusual wear patterns on seal I.D. / O.D.
or o-ring energizer (extruded).
14. Replace (Polypak Seal #10) seal. Clean entire piston assembly. Grease generously (Cylinder #12) I.D. and
entire (Piston #2) assembly.
15. Stand (Piston #2) assembly in a vertical position. Lift (Cylinder #12) assembly over and down onto piston
assembly. Align (Top Shaft #1) and bore of cylinder. Gentlylower cylinder and piston assembly. The piston
movement into the cylinder will be smooth. Push piston assembly into bore until (Top Shaft #1) is exposed.
Thread 3/4 - 10 UNC-2A lifting eye into top shaft completely.
16. Lift (Cylinder #12) assembly and lower into actuator (Housing #22). Be sure cylinder shoulders on (Housing #22).
17. Install (Housing Shear Ring #14) and (Housing Lock Ring #13). CAUTION: The shear ring must seat properly
into groove. The (Housing Lock Ring #13) must fit into space correctly. If the housing lock ring is cocked or
wedged the housing shear ring is not installed properly. In this case, remove housing shear ring, clean groove and
reinstall. CAUTION: Both rings must be installed properly.
18. Install four (Bolts #15) and (Washers #29) into top of APH Actuator. Tighten firmly. Use neverseez lightly.
19. Reconnect all accessories to Actuator, and piping and valves to present entry port on Actuator Cylinder.

page 24

FIELD REMOVAL AND REPLACEMENT OF TOP SHAFT PACKING


RETAINER SEAL
This procedure can be performed with the actuator bonnet and gate valve installed on a wellhead or flow-line.
The actuator bonnet and valve can be mounted in the horizontal or vertical position. The gate valve does need to be
in the fully closed position with the actuator top shaft extended. The fully closed position of the reverse acting gate
valve positions the bonnet stem in the back seated fire-safe mode. Tools required for field removal of bonnet seals
are adjustable wrenches, large and small; pipe wrench - large; packing extraction tool, safety glasses, hard hat
and safety boots.

PROCEDURE
The following procedure should be followed in all cases of disassembling a production hydraulic actuator. When
replacing bonnet packing seals the actuator must be removed from the bonnet assembly.
1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set
aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
6. Remove (Retainer Ring #11) from top to (Top Shaft Packing Retainer #7) in a counter clockwise direction.
CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is
noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged.
CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING!
7. Remove (Polypak #10) with extraction tool.
8. Replace with new (Polypak #10). Inspect sealing I.D. and O.D. with fingertips. Grease generously. Install
(Polypak #10) by pushing down into bore of (Cylinder #12). The o-ring energizer will face downward toward gate
valve when installed. Push until seal stops on shoulder.
9. Reinstall (Top Shaft Packing Retainer #7) by rotating in a clockwise manner until coming to a dead stop.
10. Install (Retainer Ring #11) into top of (Cylinder #12). CAUTION: Be sure to seat retainer ring into groove.
11. Reconnect all accessories to actuator and piping and valves to pressure entry port on actuator cylinder.

page 25

FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING


1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set
aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.

1. Using an adjustable wrench remove the four (Bolts #15) and (Washers #29) from the base of the Actuator
(Housing #22), set aside.

2. Remove (Housing Lock Ring #13) and (Housing Shear Ring #14), set aside. Leave on Bonnet.

3. Install two 3/4-10UNC-2A forged lifting eyes into side of (Cylinder #12)

4. Thread into two holes in (Cylinder #12). Make up thread completely.

5. With an overhead lifting device connect to the two lifting eyes and lift actuator off of the spring cartridge.
Set actuator down on clean, flat surface. Leave the two lifting eyes in place.

6. Using a large adjustable wrench, rotate (Spring Adjusting Nut #16) in counterclockwise direction. You are
relaxing the spring load from installed position to the free length position.

7. Remove (Spring Adjusting Nut #16) and set aside.

8. Remove (Upper Spring Plate #18), (Spring Guide Tube #19) and (Lower Spring Plate #20) from spring
assembly and set aside.

9. Lift (Inner Spring #21) off (Bonnet Ring #24) and set aside.

10. Remove (Drift Shims #31)

11. Leave (Stem Nut #17) in place.

12. With (Bonnet Stem #30) back seated, rotate (Packing Retainer #32) in a counterclockwise direction. Use
a medium to large pipe wrench. CAUTION: Be careful not to nick the sealing surface O.D. of the (Bonnet
Stem #30). With the removal of the packing retainer a hissing noise may be evident indicating trapped
pressure and well condensate. Be very careful with eye and hand protection. Remove packing retainer,
lift off of bonnet stem and set aside.

13. Remove (Polypak Seal #35) four rings. Use pick to pull ring out of bore. Set old packing aside.

14. Grease packing bore generously. Install (Polypak Seal #35) with o-ring energizer facing down. Do not
use pointed or sharp objects to push packing down into bore. Set all four pieces of packing completely.

page 26

15. Reinstall (Packing Retainer #32). Tighten firmly.

16. Install same number of (Drift Shims #31) onto packing retainer.

17.Check (Stem Nut #17) to insure that is fully threaded onto bonnet stem. Check (Socket Head Cap
Screws #6) for threaded engagement. They must be tight

18. Install the (Inner Spring #21) onto the (Bonnet Ring #24) springs are at free length position.

19. Place the (Upper Spring Plate #18) onto top of spring set, align spacing.

20. Insert (Spring Guide Tube #19) into bore of (Upper Spring Plate #18). Must shoulder properly.

21. Place (Lower Spring Plate #20). Down into bore of (Spring Guide Tube #19).

22. Thread (Spring Adjusting Nut #16) onto (Stem Nut #17) in a clockwise manner. Use a large adjustable
wrench to load the spring set. Continue rotation until (Stem Nut #17) stops on the (Spring Adjusting
Nut #16) shoulder. Note: the springs may rotate. This is normal and presents no cause for alarm.

23. Engage the two lifting eyes with the overhead lifting device. Lift the actuator over and down onto
(Bonnet Ring #24). The Actuator should stop correctly on the shoulder of the bonnet ring.

24. At the bottom of the Actuator install the (Housing Shear Ring #14). The ring must seat into the groove
and be tight.

25. Install the (Housing Lock Ring #13) into groove space. The ring cannot lock or wedge on the groove.
If this occurs remove both rings and clean housing groove and reinstall.

26. Install four (Bolts #15) and (Washers #29).

27. Remove lifting eyes from (Cylinder #12). Reconnect all accessories to actuator. Connect all piping and
valves securely to pressure entry port on actuator cylinder.

page 27

BURST DISC REPLACEMENT

page 28

The burst assembly incorporates four (4) components. The body, cap, disc and disc seat. The following instructions
explain the correct method to replace the burst disc assembly.

PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box/open end wrench, engage the hex wrench flats on the burst disc housing.
Using a second wrench (adjustable/open box) engage the hex flat on the burst disc cap. (Figure 1) Rotate the cap
in a counterclockwise direction until completely disengaged. (Figure 2) Remove disc seat and metallic particles of
exhausted disc. Clean inner bore and threads from burst disc housing. Install disc into bore. (Figure 3 & 4)
Caution: The convex surface of the disc must be facing outward at the installer. (Figure 5) Carefully inspect the
disc prior to installation. Make sure the contact surface of the body is clean for the disc to seal. Install the disc seat
on top of the disc center carefully. The disc seat can be installed from either side as it is symmetrical. (Figure 6)
Engage hex wrench flats on burst disc cap with an adjustable/open end wrench. Rotate the cap in a clockwise
direction. Tighten securely. (Figure 7)

PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box open end wrench, engage the hex wrench flats on the burst disc housing.
Firmly, rotate the housing in a counterclockwise direction. Caution: Do not work over the housing during removal.
Remove housing from actuator. Clean all Teflon tape or liquid residue from internal and external threads before
replacement. Wrap Teflon tape in opposite direction to normal thread engagement around the threaded end of
the housing. Wrap securely. If Teflon liquid is used apply generously. Thread housing in actuator. Rotate in a
clockwise direction. The recommended torque for tightening the burst disc cap is 50 to 65 ft./lbs. The burst disc
assembly is ready for pressure service.

Figure 1

Figure 2

page 29

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

SERVICING ARRAY MODEL APH ACTUATORS


1. Prior to servicing the actuator assembly, it is recommended that this manual be read in its entirety. Should the
service technician have any questions or feel that a certain procedure cannot be performed safely, contact the
factory for assistance.
2. For safety precautions and due to the weight and/or size of some actuator assemblies and the presence of pressurized fluids in the actuator and valve, personnel should be wearing the proper safety equipment such as steel toe
shoes, hard hats, safety goggles and lifting support belts.
3. When moving an actuator assembly or heavy parts, suitable lifting devices such as hoists and a come-a-long should
be used. It is recommended that the weights of the equipment being serviced be obtained from the appropriate gate
valve manufacturers technical bulletins to confirm that any lifting equipment to be used is adequate. CAUTION:
When using lifting eyes make sure they are forged single piece design. Engage thread completely before lifting.
4. DO NOT attempt to remove any items from the actuator assembly when it is pressurized. BLEED OFF ALL control
pressure and disconnect the supply lines before performing any service functions. Failure to do so could result in
equipment damage or personal injury.
5. The work area should be clean and free of contaminants such as dirt, sand and metal shavings etc.
6. All grease or lubricants must be free of any contaminants. Any utensils such as brushes or applicators must also be
free of any foreign particles.
7. All tools used should be clean, in good working order and be the proper tool for the operation to be performed.
8. Keep all elastomers and/or replacement parts in the original storage or shipping packaging until installed.
9. Cleaning must be finished prior to installation or inspection of any new or used component. A suitable fluid should
be used that is compatible with the part being cleaned. Most naphtha based solvents are good for heavy de-greasing
of metallic parts. A solution of warm soap and water is recommended for all non-metallic pieces or simply wipe
with a clean cloth. The use of commercially available aerosol dispensed brake cleaners may be used on metal parts
only. CAUTION: if the part is coated, test the vapor build up if using indoors.
10. A
 ll new or used parts must be examined after cleaning for burrs, dings, anomalous marks cut, nicks etc. prior to
using them
11. Lightly lubricate all seals and sealing surfaces with a suitable grease prior to installing them.
12. When handling any parts that have sealing surfaces, care should be taken not to mar those surfaces
13. C
 AUTION: Failure to follow the procedures given in this manual may result in equipment damage, operating
problems and/or personal injury.

page 30

TESTING

page 31

1. The new assembled actuator will be tested per API 6A, latest edition. The following section applicable is 10.16.5.

a. Verify the following that all mechanical lock open devices are removed when proceeding with operational testing and back seat testing.

b. Hydrostatic testing of actuator, bonnet and gate valve may employ a mechanical override only.
NO LOCK CAPS ARE TO BE USED ON HYDROSTATIC.

c. Remove the pressure relief device from the actuator. After testing is complete the safety relief device
will be assembled to the actuator. Use a gauge or solid plug as a replacement.

d. In house testing will use hydraulic/nitrogen for functional testing. If problems arise during testing with
the actuator, disassemble. Repair and re-assemble.

e. All testing must be performed by certified assemblers and testers.

PERIODIC MAINTENANCE
The following maintenance schedule is recommended to insure safe and reliable operation of the Array
Model APH Actuator.

MAINTENANCE OPERATION

Cycle actuator under normal operating conditions.

Monthly

2.

Replace pressure relief device (Burst Disc).


Check for leakage around threads.

Monthly

3.

Inspect Top Shaft

Monthly

4.

Inspect bolts and washers on top and bottom of actuator.

Monthly

Check top shaft packing retainer and retainer ring


in top of cylinder

Monthly

1.

5.

INTERVAL

TROUBLESHOOTING

page 32

TROUBLE


 ontrol Pressure in
C
Actuator Will Not Build

Actuator Will Not Stroke on


a Valve Whether or not Valve
is Pressurized

Actuator Will Not Attach to


Bonnet Assembly

PROBABLE CAUSE

Damaged control line

REMEDY
Inspect control line for damage and/or
leaking fittings

Insufficient pressure in
control line

Install gauge at pressure source to


verify desired available

Verify pressure gauge is correctly


calibrated

Faulty pressure gauge

Leak around top and/or


bottom of actuator

Replace and/or inspect seal in


accordance with assembly instructions

Insufficient pressure in
control line

Verify pressure availability from


source. Consult control pressure
information from the information chart
per size valve application

Consult appropriate maintenance and


operating instructions for bonnet

Bonnet to bonnet stem binding

Valve and/or seats improperly


installed

Remove actuator as instructed per this


manual. Remove bonnet as per bonnet
manufacturers operating instructions.
Repair and/or replace valve components as per valve manufacturers
repair manual

Debris in valve body and


actuator vents

Remove actuator as instructed per this


manual.Remove bonnet as per bonnet
manufacturers operating instructions.
Clean debris from valve body

Debris in shaft or housing

Re-inspect housing and spring

Bonnet stem is not fully


extended and back seated

Grasp stem in bonnet and pull to


full extension,properly back
seating system

Bad or wrong thread on bonnet


stem and down-stop on
bonnet/spring assembly

Check threads on bonnet stem and


down-stop plate for burrs, nicks, dings
and debris. Check size and thread
pattern for proper engagement

Spring cartridge too long


because of bonnet
engagement to down-stop

Check thread engagement on bonnet


stem and down-stop. Check for
positive distance between down-stop
and drift spacers on packing retainer

TROUBLESHOOTING

TROUBLE
Actuator Will Not Stroke
To Full Closed or Fail Safe
Close Position

Actuator Housing Stops


Prior to Aligning with
Bonnet Ring

page 33

PROBABLE CAUSE

REMEDY

Gate and seats are improperly


installed causing excessive
friction

Remove actuator as instructed per this


manual. Manually push and/or pull
bonnet stem to determine severity of
binding. If severe, remove bonnet and
gate and seats, clean and inspect gate
and seats for wear and abrasion.
Replace if necessary.

Excessive seal friction due


to lossof lubrication in
bonnet/valve

Actuate valve several times and

Improper gate to stem


engagement

Remove actuator as instructed per this

Bonnet ring not threaded


down to positive stop

Check for thread engagement between


stem nut and spring adjusting nut

lubricate valve in accordance with


manufacturers maintenance manual
manual. Remove bonnet as per bonnet
manufacturers operating instructions.
Check engagement per valve manufacturers instructionsand/or drawings,
re-assemble. This problem only
appliesto certain valves.

MODEL APH HYDRAULIC ACTUATOR


page 34

ACTUATOR SPECIFICATIONS
Maximum Operating Pressure:
Test Pressure:
API Material Class:
API Temperature Rating:
API Performance Requirement:
Can be certified for Offshore SSV:

5,000 psi / 345 bars


7,500 psi / 518 bars
BB
P -20 F to 180 F (-29 C to -82 C)
PR-2, Annex F
Yes

BONNET SPECIFICATIONS
Bonnets Available for Valve Brands:
Size Range Available:
Pressure Ranges Available:
API Material Classes Available:



Any Manufacturer (with Current Interface Drawing)


API 6A 113/16" through 71/16"
See Control Pressure Chart
AA,BB,CC (non-NACE)
DD-0,5 / DD-1,5 / DD-NL
EE-0,5 / EE-1,5 / EE-NL
FF-0,5 / FF-1,5 / FF-NL
HH-NL

API Product Specification Levels Available:


API Performance Requirement Available:
API Temperature Ratings Available:
Can be certified for Offshore SSV:

PSL - 1, 2 or 3, Annex F
PR-1 or 2
L through X
Yes

LIMITED PRODUCT WARRANTY


The following warranty is exclusive and in lieu of all other
warranties. Whether express, implied or statutory, including,
but not by way of limitation, any warranty of merchantability
or fitness for any particular purpose.
Array Products warrants to each original buyer of products
manufactured by Array that such products are free from defects
in material and workmanship under normal use and service for a
period of one (1) year from the date of shipment provided that no
warranty is made with respect to: Any product which has been
repaired or altered in such a way in ARRAYs judgment, as to
affect the product adversely; Any product which has, in ARRAYs
judgment, been subject to negligence, accident or improper
storage; Any product which has not been operated or maintained
in accordance with normal practice and in conformity with
recommendations and public specification of Array.

ARRAYs obligation under this Warranty is limited to use


reasonable efforts to repair, replace or, at its option, refunding
the purchase price. The cost of labor for installing a repair or
replacement product shall be borne by Purchaser. Replacement
parts provided under the terms of this Warranty are warranted for
the remainder of the warranty period of the products upon which
they are installed to the same extent as if such parts were original
components thereof. Warranty services provided there under do
not assume any liability for damages caused by any delays
involving warranty service. For complete specification information,
prices and name, address and telephone number of the ARRAY
representative nearest you, call or write to us at the address below.

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


ARRAY PRODUCTS
4520 E. Chandler Road, Muskogee, Oklahoma 74403
Phone: 918.682.7952 Fax: 918.682.7904 Toll Free: 866.445.1837 www.arrayproducts.com

2007 Array Holdings, Inc. All specifications and materials are subject to change without notice.

OPERATION & MAINTENANCE MANUAL

MODEL APHW
HYDRAULIC ACTUATOR

TABLE OF CONTENTS
I.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

II.

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

III.

Actuator Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

IV.

Actuator Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

V.

Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

VI.

Gate Valve Sizing Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

VII.

Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

VIII.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

IX.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

X.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

XI.

Sizing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

XII.

Actuator Valve Sizing Chart Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

XIII.

Actuator/Bonnet Assembly Drawing & Bill of Material . . . . . . . . . . . . . . . . . . . . . 14

XIV.

Sub-Assembly Operations

Piston Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Piston Sub/ Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

XV.

Bonnet Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

XVI.

Bonnet to Gate Valve Assembly/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . 18

XVII.

Main Actuator Bonnet and Gate Valve Assembly/ Assembly Drawing . . . . . . . . . . . . . 19

Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

XVIII. Setting the Gate Valve Drift/Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . 22


Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

XIX.

Field Removal and Replacement of Actuator Seal & Top Cylinder Seal . . . . . . . . . . . . 24

XX.

Field Removal and Replacement of Piston Seal . . . . . . . . . . . . . . . . . . . . . . . . . 25

XXI.

Field Removal and Replacement of Top Shaft Packing Retainer Seal . . . . . . . . . . . . . 26

XXII.

Field Removal and Replacement of Bonnet Seal Packing . . . . . . . . . . . . . . . . . . . . 27

XXIII. Burst Disc Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28


XXIV. Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
XXVI. Testing and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
XXV.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

XXVI. Product Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

page 2

INTRODUCTION
The Array model APHW is a Hydraulic Wire Cutting Actuator. This actuator is designed as a fail closed operator.
The SSV APHW Hydraulic Wire cutting Actuator should be installed on the second valve in the wellhead flow
stream. When two master valves are used, the SSV should be the top master valve. The SSV will be tested in
accordance with procedures given in the American Petroleum Institute specification 6A, latest revision. SSVs
located in federal waters should only be serviced by technicians that meet qualifications as defined by the
Minerals Management Service (MMS).
This installation and maintenance manual gives factory required assembly, disassembly and installation
procedures, trouble shooting and technical specifications.
Typical uses are for critical valve applications on wellhead production, drilling and exploration and pipelines.

ACTUATOR OPERATION
Array model APHW Hydraulic Wire Cutting Actuators are designed to operate Array Fail-Safe Bonnet Assemblies
used on gate valves and move them from their Fail-Safe positions. The thrust required to do this is created by
application of adequate control pressure to the actuator inlet port. Hydraulic pressure acting on the piston
overcomes the thrust created by the forces of the valve pressure acting on the bonnet stem and gate friction due
to any pressure differential acting on the valve gate and dual set of springs. It will open fail-closed gate valves.
Removal of this control pressure allows the bonnet stem forces to return the valve gate to its fail-safe position.
The actuator return spring provides the required force to overcome dynamic seal friction and the weight of
moving parts when no pressure exists in the valve and shear a single diameter size cable or slick line wire.
When adequate control pressure is applied, the action of the actuator as noted by movement of the top shaft
will depend upon whether the valve is fail-closed and how much pressure differential is present across the
valve gate. Fail-closed valves will initially open with a sudden jerk as the gate cracks open and the pressure
differential is reduced. This is normal and does not damage the valve or hinder its function. The severity and
travel of this rapid motion depends on the amount of pressure differential across the valve gate. The greater
the differential, the more rapid the motion for a longer amount of the total valve stroke. The remainder of the
actuator motion should be smooth and uniform.
Upon removal of control pressure from actuators mounted on fail-closed valves, the motion should be smooth
throughout the entire stroke. Speed of this action depends on many factors such as how fast a differential
builds across the gate, is a locally mounted valve being used to exhaust the control pressure and the size of the
actuator and valve. As a general rule, the faster the control pressure is removed from the actuator the quicker
it will close.
The combination of compression spring assembly will provide approximately 8,000 pounds of force in the
closed position of the gate valve.

page 3

ACTUATOR TECHNICAL SPECIFICATION

1.

Applicable Gate Valve Bore

113/16" thru 71/16"

2.

Applicable Gate Valve W.P.

2M thru 15M

3.

API Classification

6A

3.

Trim (API 6A material Class)

BB

4.

Product Specification Level (PSL)

5.

Performance Rating

PR-2

6.

Temperature Classification

P -20 to 180F (-29C to -82 C)

7.

Maximum Operating Pressure

5,000 psi (345 Bars)

8.

Maximum Test Pressure

7,500 psi (518 Bars)

9.

Pressure Relief (Burst Disc) Setting (Stainless)

5,000 psi @ 130 F (345 Bars @ 54 C)

10.

Actuator Volume

See chart on page 5

11.

Weight

See chart on page 5

12.

Dimensions

See chart on page 5

page 4

MODEL APHW OPERATION AND MAINTENANCE MANUAL


ACTUATOR SIZES, DIMENSIONS, WEIGHT AND VOLUME

MODEL

in

APHW 045 x 020

3"

page 5

mm

in

29.50 749

D
mm

in

21.14 536

mm

in mm

13.25 336

2.25 57

in

mm

2.50 63

APHW 045 x 030

30.50 774

21.14 536

13.25 336

2.25 57

2.50 63

APHW 045 x 040

31.50 800

21.14 536

13.25 336

2.25 57

2.50 63

APHW 045 x 050

32.50 825

21.14 536

13.25 336

2.25 57

2.50 63

APHW 045 x 060

33.50 850

21.14 536

13.25 336

2.25 57

2.50 63

APHW 065 x 040

34.50 876

27.10 688

16.96 430

2.25 57

2.75 69

APHW 065 x 050

35.50 901

27.10 688

16.96 430

2.25 57

2.75 69

APHW 065 x 060

36.50 927

27.10 688

16.96 430

2.25 57

2.75 69

APHW 065 x 070

37.50 952

27.10 688

16.96 430

2.25 57

2.75 69

B
All Upper Housing
Threads are
8 UN-2A

MODEL

SWEPT VOLUME
in3

APHW 045 x 020

cm3

34.0

557

CLOSING TIMES
seconds
23

WEIGHT
lbs

kgs

432

196

APHW 045 x 020

40.0

587

34

432

196

APHW 045 x 030

46.0

675

56

440

199

APHW 045 x 030

54.0

793

67

465

211

APHW 045 x 040

69.0

1013

89

450

204

APHW 045 x 050

84.0

1233

1011

455

206

APHW 045 x 060

98.0

1439

1112

465

211

APHW 065 x 040

150.0 2459

910

881

400

APHW 065 x 050

186.0 3049

1112

898

408

APHW 065 x 060

218.0 3573

1314

898

408

APHW 065 x 070

253.0 4147

1415

907

412

ORDERING INFORMATION
The following information should be provided when requesting a quote or issuing a purchase order to
Array Products for an APHW Actuator.

Actuator
Model of Actuator:_______________________________________________________________________________
Size of Actuator: ________________________________________________________________________________
Actuator Control Pressure Availability: ______________________________________________________________
Special Requirements:
Testing _______________________________________________________________________________________
Coating_______________________________________________________________________________________
Non-Rising Top Shaft___________________________________________________________________________
Certification / Specification_______________________________________________________________________
Cable Size and Style______________________________________________________________________________

Bonnet / Gate Valve


Gate Valve Bore Size:_____________________________________________________________________________
Rated Working Pressure of Gate Valve:______________________________________________________________
Temperature Rating: _____________________________________________________________________________
Material Class: _________________________________________________________________________________
PSL Rating:_____________________________________________________________________________________
PR Rating:______________________________________________________________________________________
Interface Drawing Availability:______________________________________________________________________

Accessories
Fusible Lock Open Cap: __________________________________________________________________________
Fusible Manual Override: _________________________________________________________________________
Hydraulic Override: ______________________________________________________________________________
Stem Protector (Clear) (Metal):_____________________________________________________________________
Electronic Switches Proximity: ____________________________________________________________________

page 6

APHW GATE VALVE SIZING MATRIX


page 7

VALVE

BORE SIZE

VALVE WORKING PRESSURE


10,000 PSI

15,000 PSI



1 1316

APHW 045 x 020


1705 psi
.116 x wp + 545 psi

APHW 045 x 020


2285 psi
.116 x wp + 545 psi




2 116

APHW 045 x 020


1845 psi
.130 x wp + 545 psi

APHW 045 x 020


2495 psi
.130 x wp + 545 psi




2 916

APHW 045 x 030


2055 psi
.151 x wp + 545 psi

APHW 045 x 030


2810 psi
.151 x wp + 545 psi

APHW 045 x 030


1625 psi
.216 x wp + 545 psi

APHW 045 x 030


2675 psi
.213 x wp + 545 psi

APHW 045 x 030


3740 psi
.213 x wp + 545 psi


APHW 045 x 040
APHW 045 x 040


1511 psi
2155 psi

4 116
.322 x wp + 545 psi
.322 x wp + 545 psi




APHW 045 x 040


3765 psi
.322 x wp + 545 psi
APHW 065 x 040
1730 psi
.148 x wp + 250 psi

APHW 045 x 040


5375 psi
.322 x wp + 545 psi
APHW 065 x 040
2470 psi
.148 x wp + 250 psi


APHW 045 x 050
APHW 045 x 050


2108 psi
3150 psi

5 18
.521 x wp + 545 psi
.521 x wp + 545 psi




APHW 045 x 050


5755 psi
.521 x wp + 545 psi
APHW 065 x 050
2640 psi
.239 x wp + 250 psi

APHW 065 x 050


3835 psi
.239 x wp + 250 psi

APHW 065 x 060


6085 psi
.389 x wp + 250 psi


3 18

3 116

3,000 PSI

APHW 045 x 030


1193 psi
.216 x wp + 545 psi

5,000 PSI




6 38


APHW 045 x 060


2855 psi
.770 x wp + 545 psi
APHW 065 x 060
1417 psi
.389 x wp + 250 psi

APHW 045 x 060


APHW 065 x 060
4395 psi
4140 psi
.770 x wp + 545 psi
.389 x wp + 250 psi
APHW 065 x 060
2195 psi
.389 x wp + 250 psi



7 116

APHW 065 x 070


1534 psi
.428 x wp + 250 psi

APHW 065 x 070


2390 psi
.428 x wp + 250 psi

APHW 065 x 070


4530 psi
.428 x wp + 250 psi

Note: The designed values provided above only apply to actuators manufactured for Array gate valves and are provided for reference only. See Note on Next Page

SIZING MATRIX APHW 045 WIRE CUTTING HYDRAULIC ACTUATOR


NOTES
1. APHW 045 x 030 Actuator size, description and bore size at maximum working pressure.
2. PSI number is total of equation and spring load to open gate valve.
3. Control pressure equation x valve working pressure + total spring load. When calculating hydraulic control
supply for the APHW use this equation.
4. All actuator force loads comply with API 6A 10.16.3.7.

ACTUATOR SELECTION PROCEDURE


Determine gate valve specifications such as size, maximum rated working pressure, projected shut-in pressure
and maximum flow line pressure. If maximum flow line pressure is one half or less than the maximum working
pressure of the gate valve consult the actuator size chart for the optimum actuator size.

DETERMINE ACTUATOR CONTROL PRESSURE SUPPLY


Determine maximum flow line pressure in gate valve. What is the available hydraulic pressure supply at site?
Multiply the maximum flow line pressure by the matrix equation and add the remaining number of psi for the
total hydraulic pressure to be used to open gate valve.

page 8

APHW SIZING CHART


page 9

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page 10

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APHW SIZING CHART


page 11

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page 12

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ACTUATOR VALVE SIZING CHART PROCEDURE


page 13

1. To select the proper actuator size and control pressure you must first determine the
gate valve bore size and the maximum working pressure of the valve.
2. Now determine the maximum flowing and shut in pressure for production.
3. Determine the available hydraulic control supply pressure at location.
4. Using the appropriate gate valve bore chart, find the y-axis location and draw a vertical line to the top of the chart.

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5. As the y-axis vertical line crosses the existing actuator control pressure line that intersecting point defines the minimum
required actuator control pressure to open the gate valve.

Example: A valve pressure of 8,400 psi requires an actuator hydraulic control pressure of 3,250 psi to open gate valve (APHW
045 x 040). See control pressure equation on pages 7 & 8.

PARTS LIST
page 14

1
7
#

DESCRIPTION

Top Shaft

Piston (AK)

Polypak Seal (AK)

Wear Bearing (AK)

Top Shaft Retainer Plate

Socket Head Cap Screw

Top Shaft Packing Retainer

Rod Wiper (AK)

Wear Bearing (AK)

10

Polypak Seal (AK)

11

Retainer Ring

12

Cylinder

13

Housing Lock Ring Inner

14

Housing Shear Ring Inner

15

Cylinder Adapter Ring

16

Housing Lock Ring Outer

17

Housing Shear Ring Outer

18

Hex Head Bolt

19

Spring Adjusting Nut

20

Stem Nut

21

Upper Spring Plate

22

Spring Guide Tube

23

Lower Spring Plate

24

Spring, Helical Inner

25

Spring, Helical Outer

26

Housing

27

Socket Head Set Screw

28

Bonnet Ring

29

Relief Valve

30

Caution Tag (NS)

31

Nameplate (NS)

32

Drive Screws (NS)

33

Washer

34

Washer

8
11
12

9
10
29

4
2
13
14

Stem

36

Drift Shim

37

Packing Retainer

38

O-Ring (BK)

39

O-Ring (BK)

40

Polypak Seal (BK)

41

Bonnet

42

Vent Fitting

43

Nameplate (NS)

44

Drive Screws (NS)

(NS) = Not Shown


(AK) = Actuator Redress Kit Items
(BK) = Bonnet Redress Kit Items

18
33
16
17

21
19

15

20
22

26

23
35
36

38

27

25

24

37

28
39
16

BONNET
35

17
40

41

34
18

42

Parts list includes items in a typical bonnet assembly. Some differences may exist in bonnets for valves
manufactured by companies other than Array Products. In those cases the specific differences are usually
limited to the design of the bottom of the bonnet and operating stem.

SUB ASSEMBLY OPERATIONS


The following procedure outlines the assembly of the actuator. The sub assemblies will be combined into the
main assembly.
It is important that the assembly area be clean and free of all dirt particles and any other solid that could impede
proper assembly cleanliness..

PISTON SUB ASSEMBLY


1. Inspect (Piston #2) one each, for dings, nicks or scratches. Clean
thoroughly, inspect sealing surfaces.
2. Lightly cover entire piston with high grade lubricant and set aside.
3. Inspect (Top Shaft Retainer Plate #5) one each, verify that holes and
surfaces are clean and free of debris.
Lightly grease.
4. Examine (Top Shaft #1) one each, verify finish on seal surface.
Lightly grease.
5. Socket (Screw #6) four each, (Wear Bearing #4) one each, conclude
piston assembly.
6. Check (PolypakTM Seal #3) for marks and cuts. Inspect energizer
o-ring for surface imperfections. Check the sealing edges (O.D./I.D.)
carefully by moving fingertips over the surfaces.
7. Place piston on flat clean surface with tapped holes facing upward.
Grease sealing diameter and shoulder. Place PolypakTM over piston
groove and push down gently. The PolypakTM o-ring should be facing
upwards. Seat firmly
on shoulder.
8. Install top shaft base vertically into counter bore of piston. Seat firmly
by hand. Set top shaft retainer plate over
and down onto top of piston. Align four holes on the top shaft retainer
plate to the four tapped holes in the piston. Apply neverseez lightly to
threads. Install all (Screws #6). Tighten in clockwise direction. Apply
25 to 30 ft. lbs
of torque each.
9. Wipe wear bearing surface clean and install (Wear Bearing #4).
The bearing must fit snug with no overlap. The bearing is skive cut
and must fit with little or no gap.
10. The piston assembly in now complete. Set aside.

page 15

TOP SHAFT PACKING RETAINER SUB ASSEMBLY


1. Inspect (Top Shaft Packing Retainer #7) threads and sealing surface. Check for broken or torn threads. Be sure that
bore is smooth and bearing groove is clean of debris.
2. Install (Rod Wiper #8) into top groove of top shaft packing retainer. Inspect rod wiper for tears. Do not grease.
3. Install (Wear Bearing #9) into internal groove of top shaft packing retainer. Make sure bearing is seated into groove
properly. No overlap is permitted. The top shaft will not move freely through top shaft packing retainer if bearing is not
properly seated.
4. Set top shaft packing retainer aside.

CYLINDER SUB ASSEMBLY


1. Inspect all surfaces on (Cylinder #12) threads for tears and burrs.
Inspect bore with hand for ripples, tears, high spots and surface finish.
Check top bore for thread tears and surface finish. Check lead in angle
at large opening for smooth entry. Inspect two 1/2 nptf tapped holes for
tears or burrs. Clean entire cylinder and grease lightly.
2. Place cylinder in a vertical position with O.D. threads at top.
3. Install (Wear Bearing #9) into bore of (Top Shaft Packing Retainer
#7). Clean bore prior to installation. Wear bearing must fold cleanly
into bore. No overlap, skive cut must be clean.
4. Grease top sealing bore generously. Insert (Polypak #10) with o-ring
energizer facing downward. Polypak will stop on shoulder.
5. Apply neverseez to threads on (Top Shaft Packing Retainer #7).
Insert part into top threaded bore of cylinder. Rotate part in a clockwise
direction to a positive stop. Using a wrench, torque the top shaft
packing retainer firmly.
6. Install (Retainer Ring #11) into groove located at top of cylinder
threaded boss.
7. Grease (Cylinder #12) generously.
8. Place piston sub assembly on a flat planer surface. Lift cylinder
sub-assembly up.
9. Align top shaft on piston with bore of cylinder, lower cylinder down and
over piston. The piston should enter the cylinder bore smoothly. After
the piston has entered bore of cylinder rotate cylinder and piston
assembly to the horizontal position. Continue pushing the piston by
hand into the bore of the cylinder until top shaft has extended through
the top shaft packing retainer. At this point,
thread lifting eye into top shaft. Lift the entire assembly and set
aside. The weight of the assembly will force the piston to travel further
into the cylinder bore until reaching a positive stop.

page 16

ARRAY BONNET ASSEMBLY


The bonnet is part of the actuator that connects the actuator to the valve. The following outlines the assembly of the
Array Bonnet Assembly. All item numbers correspond to Bill of Material items. CAUTION: It is imperative that when
assembling the Bonnet, the assembly area be clean and free of all flying debris.

PROCEDURE
1. Examine the (Packing Retainer #37). Verify that bore
threads are clean and in good condition and o-ring grooves
are clean and in good condition.
2. Thoroughly clean the (Packing Retainer #37), removing all
foreign debris from the threads and o-ring grooves.
3. Thoroughly lubricate the entire part with assembly lubricant
and then set aside.
4. Examine the (Bonnet #41). Verify that bore and threads are
clean and in good condition.
5. Thoroughly clean the Bonnet bore and O.D. threads and
lightly lubricate packing box with assembly lubricant.
6. Install the (Polypak Seal #40) in the bonnet packing box
with the packing o-ring energizer facing down. Push the
packing rings down to a positive stop.
7. Pick up the Packing Retainer and carefully thread the
retainer into the Bonnet with clockwise rotation to a positive
stop. Tighten retainer securely with a pipe wrench. Remove
any metal shavings or bits of residue from wrench operation.
8. Install a 1/2" (Body Grease Fitting #43) in the tapped hole in
the Bonnet flange and tighten fitting securely. Use pipe tape
or liquid (Teflon).
9. Examine the (Bonnet Stem #35). Verify that threads are
clean and in good condition, seal surface is clean and free of
nicks, dings, burrs and scratches.
10. Lightly lubricate the entire seal surface of the stem with
assembly lubricant.
11. Pick up the Bonnet and place it on its side.
12. Pick up the Stem and pass the Stem through the Bonnet
and packing set, from the flange side of the Bonnet until
the Stem backseat contacts its stop point. CAUTION: Be
careful not to nick I.D. sealing surface of packing by nose
of bonnet stem. Note: The design of the Stem/Gate
connection will vary depending on size, working pressure
and manufacturer.

page 17

page 18

ARRAY BONNET TO GATE VALVE ASSEMBLY


The Array Products Bonnet Assembly when installed on an unbalanced valve is the interface between the Actuator and
the gate valve. The Bonnet will provide leak free sealing. Before adapting the actuator the bonnet stem should be
stroked freely by hand in both directions. When the valve is pressured in the full closed position the stem will be urged
outward because of the valve pressure acting on the bonnet stem diameter.
The Array Products bonnet is used as an up and down stop for the valve. This design prevents damage to the valve
bonnet stem in the event of accidental over pressuring of the actuator.
The bonnet provides positive stroke reliability by use of spacers (provided with the actuator). Once proper stroke has
been set, a constant stroke distance will be maintained though the normal service life. All Array bonnet assemblies are
shipped ready for installation on the valve.
WARNING: During installation pay special attention to removal of any devices on the valve such as stem balancing
components, internal gate down stop devices and any adjustments to gate travel.

PROCEDURE
1. Push the (Bonnet Stem #35) down out of the (Bonnet #41) until the
stem end for gate adaptation is exposed.
2. Thread the gate onto the exposed portion of the stem in a closing
direction. Position gate as required by valve manufacturers installation
procedure.
3. Rotate the gate slightly in either direction to align the slot in the stem
with the mating hole in the gate lift nut. Drive the pin (supplied by the
valve) through the gate pin hole in the stem slot.
4. Install new bonnet seal ring (supplied with the valve) in the valve body
and then carefully lower the gate into the valve body, between the seats
and allow the bonnet to pass over the valve body stud.
5. Install the valve body nuts on the studs and make up connection as
required by valve manufacturer.
6. The (Bonnet Stem #35) should slide easily upwards by pulling the gate
up to the fully closed position with your hands. The (Stem Nut #20) can
be threaded onto the stem for better leverage. Do not use any other
device or tool to lift the (Bonnet Stem #35) to the fully closed position
other than previously mentioned.

page 19

MAIN ASSEMBLY ACTUATOR ASSEMBLY TO BONNET AND GATE VALVE


1. The Bonnet Assembly is installed on a reverse acting gate valve. (See bonnet to gate valve assembly) and the drift
properly set with the correct amount of shims. (See setting the valve drift section).
2. With bonnet and valve assembly in the vertical position, install (Stem Nut #20). Rotate in a clockwise direction to a
positive stop. Using wrench, tighten firmly.
3. Install two (Socket Head Set Screws #27). Use neverseez sparingly. Tighten both screws securely. Caution: inspect
both screw engagement into stem nut. No protrusion of either screw is permitted as this will interfere with assembly
of spring adjusting nut.
4. Place (Housing Lock Ring #16) and housing (Housing Shear Ring #17) down onto flange of bonnet. They should
remain loose. They will be used upon addition of (Housing #26).
5. Place (Bonnet Ring #28) onto threaded nose of bonnet. Apply neverseez to I.D. threads on bonnet ring. Rotate the
bonnet ring counterclockwise to locate the thread start and then clockwise to a positive stop. Grease top portion of
bonnet ring generously. The springs will rotate when being compressed. Tighten bonnet ring securely, lock threads.
6. Place the (Inner Spring #24) down onto face of bonnet ring.
7. Place the (Outer Spring #25) over and down onto face of bonnet ring. Center both springs by hand. They must be
evenly spaced.
8. Place the (Upper Spring Plate #21) down on top of the inner and outer spring set. Align the ring of the plate to match
the O.D. and I.D. of the spring set.
9. Install the (Spring Guide Tube #22) into the bore of the upper spring plate. The tube shoulder will nest inside of the
spring plate.
10. Place the (Lower Spring Plate #23) into the bore of the spring guide tube until the lower spring plate shoulder
stops on the inner shoulder of the spring tube.
11. Thread the (Spring Adjusting Nut #19) onto the (Stem Nut #20) O.D. threads in a clockwise rotation. An adjustable
long wrench will be required. Rotate to a positive stop. The two springs are fully loaded at this point. Note: the
springs may rotate when being compressed. This action is normal and presents no cause for alarm.
12. Lift the housing carefully over the assembled bonnet and spring cartridge. The (Housing #26) will stop on the
shoulder of the (Bonnet Ring #28) on bonnet end.
13. Insert the (Housing Shear Ring #17) into the groove in the housing. CAUTION: Make sure ring is seated and sprung
outward on bonnet end. (Must fit tight in groove).
14. Insert (Housing Lock Ring #16) into groove inside of housing shear ring on the bonnet end. Note: if for any reason,
the lock ring does not install easily or is cocked in the groove, remove and reseat shear ring, then reinstall lock ring.
15. Install four (Washers #34) and (Bolts #18) into four tapped holes in bottom of bonnet ring. Apply neverseez lightly
to threads . Wrench torque firmly.
16. Install (Cylinder Adapter Ring #15) into top of (Housing #26) Note: check for proper fit of shoulders.
17. Insert the (Housing Shear Ring #17) in the groove in the top end of housing. CAUTION: Make sure ring is seated and
sprung outward. (Must fit tight into groove).
18. Insert (Housing Lock Ring #16) into groove inside top end of housing shear ring. Note: If for any reason the lock
ring does not install easily or is cocked in the groove remove and reseat shear ring, then reinstall lock ring.

page 20

19. Using lifting eye installed in top shaft, lift cylinder and piston assembly into bore of cylinder (Cylinder Adapter Ring
#15). CAUTION: be careful when lowering assembly for proper alignment. The cylinder and piston assembly will
stop on cylinder adapter ring shoulder. Remove lifting eye from top shaft.
20. Insert the (Housing Shear Ring #14) into the groove in the (Cylinder Adapter Ring #15). CAUTION: Make sure ring
is seated and spring outward. (Must fit tight into groove).
21. Insert (Housing Lock Ring #13) into groove inside of housing shear ring. Note: if for any reason the lock ring does
not install easily or is cocked in the groove remove and reseat shear ring, then reinstall lock ring.
22. Install four (Washers #33) and (Bolts #18) into four tapped holes in top of (Cylinder Adapter Ring #15). Apply
neverseez lightly to threads. Using wrench torque firmly.
23. Install a solid 1/2 npt plug in one of the tapped holes located at the top of the (Cylinder #12). The solid plug should
be sealed with Teflon tape or Teflon liquid sealant. Plug to remain during testing.
24. Apply (Nameplate #31) using four (Drive Screws #32) See illustration (Not Shown).
25. Apply (Caution Tag #30) to O.D. of cylinder. Must be in close proximity to safety relief device. (Not Shown)
26. Actuator testing can now begin. Consult section of actuator testing.

MAIN ASSEMBLY ACTUATOR ASSEMBLY TO BONNET


AND GATE VALVE

page 21

SETTING THE GATE VALVE DRIFT


1. Setting the drift can only be accomplished after the bonnet assembly has been installed on the gate valve. All studs
and bolts have been torqued with all stem to gate connections completed.
2. With the gate valve in the vertical position, place four (Drift Shims #36) on top of the packing retainer.
3. Thread the (Stem Nut #20) onto the bonnet stem to a dead stop.
4. Using both hands, push down on the stem nut to bottom out on top of the shims.
5. Check the drift alignment by running the appropriate size drift tool through the bore. If the gate is not aligned with
the valve bore, pull up on the stem to the fully closed position and remove the down stop and add or subtract shims
as required to properly align the gate with the gate valve bore. (See Illustration)
6. The stroke length is now set permanent.

page 22

page 23

GATE
GATE

ADD SHIMS

REMOVE SHIMS

FIELD REMOVAL AND REPLACEMENT OF ACTUATOR SEAL


This procedure can be performed with the actuator installed on the bonnet and gate valve. The actuator can be
mounted in the horizontal or vertical position. The large coil springs and housing does not need to be removed.
The gate valve does need to be in the fully closed position with the top shaft fully extended. This fully closed position
of the reverse acting gate valve position the bonnet stem in the back seated fire safe mode.
Tools required for field disassembly are adjustable wrench large and small; large and small blade screwdrivers;
set of allen wrenches, o-ring extraction tool; safety glasses; hard hat and safety boots.
PROCEDURE
The following procedures should be followed in all cases of disassembling a production hydraulic actuator. When
replacing the actuator seals (2 each) from the cylinder follow these directions carefully.
1. Disconnect power source going to Actuator inlet. Be careful not to spill hydraulic fluid.
2. Do not disconnect the pressure relief device.
3. If a high pressure quick exhaust valve is used, disconnect from Actuator and set aside.
4. If electronic proximity switches are installed remove from top of cylinder. Do not injure or mishandle. Set aside.
5. If other accessories are mounted to the top of the Actuator remove and set aside. These accessories can be clear
stem protector, fusible manual override and fusible lock open cap. CAUTION: If a fusible lock open cap is installed
on the Actuator. Prior to any disassembly pressurize actuator to full open position to release upward thrust load on
cap. This operation will prevent injury to personnel and equipment. After pressurizing actuator unscrew fusible cap
and set aside.
REPLACE TOP CYLINDER SEAL
6. Remove (Retainer Ring #11) from (Cylinder #12) threaded boss.
7. Using an adjustable wrench rotate (Top Shaft Packing Retainer #7) in a counter-clockwise direction. CAUTION:
Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is noticeable and
hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged.
CAUTION: NEVER WORK OVER ACTUATOR WHEN DISASSEMBLING.

page 24

FIELD REMOVAL AND REPLACEMENT OF ACTUATOR PISTON SEAL


1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set
aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
6. Remove 4 each (Hex Head Bolts #18) and (Washers #33) from top of APHW Actuator. Set aside.
7. Remove (Housing Lock Ring - Inner #13) and set aside.
8. Using a thin blade screwdriver, remove (Housing Shear Ring - Inner #14) Note: Debris may have hidden milled
removal slots on ring. If possible clean surface prior to removal.
9. ( Housing Shear Ring #14) should be removed easily. If for any reason ring is difficult to remove, stop and check
pressure attachment to (Cylinder #12) and check for trapped internal pressure.
10. Install 3/4 10 UNC 2A lifting eye into (Top Shaft #1) Thread complete.
11. A
 fter removal of (Housing Shear Ring #14) lift (Cylinder #12) from Actuator (Housing #26) using lifting eye.
Set assembly on flat surface.
12. Clean entire outside surface of (Cylinder #12) assembly.
13. P
 lace (Cylinder #12) assembly on a horizontal position and remove lifting eye from (Top Shaft #1) Hold (Cylinder
#12) assembly firmly. Push (Top Shaft #1) and (Piston #2) assembly out of cylinder bore. Be careful not to
mishandle piston assembly as hydraulic fluid will be present and slippery. Clean piston assembly. Remove piston
(PolypakTM Seal #10), inspect seal. Report any unusual wear patterns on seal I.D./O.D. or o-ring energizer
(extruded).
14. R
 eplace (PolypakTM Seal #10) seal. Clean entire piston assembly. Grease generously (Cylinder #12) I.D. and
entire (Piston #2) assembly.
15. Stand (Piston #2) assembly in a vertical position. Lift (Cylinder #12) assembly over and down onto piston assembly.
Align (Top Shaft #1) and bore of cylinder. Gently lower cylinder and piston assembly. The piston movement into
the cylinder will be smooth. Push piston assembly into bore until (Top Shaft #1) is exposed. Thread 3/4-10 unc-2A
lifting eye into top shaft completely.
16. L
 ift (Cylinder #12) assembly and lower into actuator (Housing #26). Be sure cylinder shoulders on (Cylinder
Adapter Ring #15).
17. Install (Housing Shear Ring #14) and (Housing Lock Ring #13). CAUTION: The shear ring must seat properly into
groove. The (Housing Lock Ring #13) must fit into space correctly. If the housing lock ring is cocked or wedged
the housing shear ring is not installed properly. In this case, remove housing shear ring, clean groove and
reinstall. CAUTION: Both rings must be installed properly.
18. Install four (Hex Head Bolts #18) and (Washers #33) into top of (Cylinder Adapter Ring #15). Tighten firmly. Use
neverseez lightly.
19. R
 econnect all accessories to Actuator, and piping and valves to present entry port on Actuator Cylinder.

page 25

FIELD REMOVAL AND REPLACEMENT OF TOP SHAFT PACKING


RETAINER SEAL
This procedure can be performed with the actuator bonnet and gate valve installed on a wellhead or flow-line. The
actuator bonnet and valve can be mounted in the horizontal or vertical position. The gate valve does need to be in the
fully closed position with the actuator top shaft extended. The fully closed position of the reverse acting gate valve
positions the bonnet stem in the back seated fire-safe mode.
Tools required for field removal of bonnet seals are adjustable wrenches, large and small; pipe wrench large;
packing extraction tool, safety glasses, hard hat and safety boots.
PROCEDURE
The following procedure should be followed in all cases of disassembling a production hydraulic actuator. When
replacing bonnet packing seals the actuator must be removed from the bonnet assembly.
1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle.
Set aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
6. Remove (Retainer Ring #11) from top to (Top Shaft Packing Retainer #7) in a counter clockwise direction.
CAUTION: Rotate slowly and be aware that pressure could be trapped inside cylinder. If a hissing noise is noticeable and hydraulic fluid is escaping, loosen top shaft packing retainer slowly until disengaged. CAUTION: NEVER
WORK OVER ACTUATOR WHEN DISASSEMBLING!
7. Remove (PolypakTM #10) with extraction tool.
8. Replace with new (PolypakTM #10). Inspect sealing I.D. and O.D. with fingertips. Grease generously. Install
(PolypakTM #10) by pushing down into bore of (Cylinder #12). The o-ring energizer will face downward toward
gate valve when installed. Push until seal stops on shoulder.
9. Reinstall (Top Shaft Packing Retainer #7) by rotating in a clockwise manner until coming to a dead stop.
10. Install (Retainer Ring #11) into top of (Cylinder #12). CAUTION: Be sure to seat retainer ring into groove.
11. Reconnect all accessories to actuator and piping and valves to pressure entry port on actuator cylinder.

page 26

FIELD REMOVAL AND REPLACEMENT OF BONNET SEAL PACKING


1. Disconnect power source going to actuator pressure inlet. Be careful not to spill hydraulic oil.
2. Do not disconnect the pressure relief device.
3. If a high pressure hydraulic quick exhaust valve is used disconnect from actuator and set aside.
4. If electronic proximity switches are installed remove them from top of cylinder. Do not injure or mishandle. Set
aside. Be aware when removing switch bracket so as to correctly install properly later.
5. If other accessories are mounted to the top of the Actuator, remove and set aside. These accessories can be clear
stem protector, fusible lock open cap. CAUTION: If fusible lock open cap is installed on the Actuator, prior to any
disassembly pressurize Actuator to full open position to release upward thrust load on cap. This operation will
prevent injury to personnel. After pressurizing Actuator, unscrew fusible cap and set aside.
1. Using an adjustable wrench remove the four (Hex Head Bolts #18) and (Washers #34) from the base of the
Actuator (Housing #26), set aside.
2. Remove (Housing Lock Ring-Outer #16), set aside.
3. Remove (Housing Shear Ring-Outer #17), set aside.
4. Install two 3/4-10 unc-2A forged lifting eyes into side of (Cylinder #12)
5. Thread into two holes in (Cylinder #12). Make up thread completely.
6. With an overhead lifting device connect to the two lifting eyes and lift actuator off of the spring cartridge. Set
actuator down on clean, flat surface. Leave the two lifting eyes in place.
7. Using a large adjustable wrench, rotate (Spring Adjusting Nut #19) in counterclockwise direction. You are
relaxing the spring load from installed position to the free length position.
8. Remove (Spring Adjusting Nut #19) and set aside.
9. Remove (Upper Spring Plate #21), (Spring Guide Tube #22) and (Lower Spring Plate #23) from spring assembly
and set aside.
10. Lift (Inner Spring #24) and (Outer Spring #25) off (Bonnet Ring #28) and set aside.
11. Remove (Drift Shims #36)
12. Leave (Stem Nut #20) in place.
13. With (Bonnet Stem #35) back seated, rotate (Packing Retainer #37) in a counter-clockwise direction. Use a
medium to large pipe wrench. CAUTION: Be careful not to nick the sealing surface O.D. of the (Bonnet Stem #35).
With the removal of the packing retainer a hissing noise may be evident indicating trapped pressure and well
condensate. Be very careful with eye and hand protection. Remove packing retainer, lift off of bonnet stem and
set aside.
14. Remove (PolypakTM Seal #41) four rings. Use pick to pull ring out of bore. Setold packing aside.
15. Grease packing bore generously. Install (Polypak Seal #41) with o-ring energizer facing down. Do not use
pointed or sharp objects to push packing down into bore. Set all four pieces of packing completely.
16. Reinstall (Packing Retainer #37). Tighten firmly.
17. Install same number of (Drift Shims #36) onto packing retainer.
18. Check (Stem Nut #20) to insure that is fully threaded onto bonnet stem. Check (Screws #6) for threaded
engagement. They must be tight.

page 27

19. Install the (Inner Spring #24) and (Outer Spring #25) onto the (Bonnet Ring #28) springs are at free
length position.
20. Place the (Upper Spring Plate #21) onto top of spring set, align spacing.
21. Insert (Spring Guide Tube #22) into bore of (Upper Spring Plate #21). Mustshoulder properly.
22. Place (Lower Spring Plate #23). Down into bore of (Spring Guide Tube #22).
23. Thread (Spring Adjusting Nut #19) onto (Stem Nut #20) in a clockwise manner. Use a large adjustable wrench
to load the spring set. Continue rotation until (Stem Nut #20) stops on the (Spring Adjusting Nut #19) shoulder.
Note: The springs may rotate. This is normal and presents no cause for alarm.
24. Engage the two lifting eyes with the overhead lifting device. Lift the actuator over and down onto (Bonnet Ring #28).
The Actuator should stop correctly on the shoulder of the bonnet ring.
25. At the bottom of the Actuator install the (Housing Shear Ring - Outer #17). The ring must seat into the groove
and be tight.
26. Install the (Housing Lock Ring #16) into groove space. The ring cannot lock or wedge on the groove. If this
occurs remove both rings and clean housing groove and reinstall.
27. Install four (Hex Head Bolts #18) and (Washers #33).
28. Remove lifting eyes from (Cylinder #12). Reconnect all accessories to actuator. Connect securely all piping and
valves to pressure entry port on actuator cylinder.

page 28

BURST DISC REPLACEMENT

page 29

The burst assembly incorporates four (4) components. The body, cap, disc and disc seat. The following instructions
explain the correct method to replace the burst disc assembly.
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box/open end wrench, engage the hex wrench flats on the burst disc housing.
Using a second wrench (adjustable/open box) engage the hex flat on the burst disc cap. (Figure 1) Rotate the cap in
a counterclockwise direction until completely disengaged. (Figure 2) Remove disc seat and metallic particles of
exhausted disc. Clean inner bore and threads from burst disc housing. Install disc into bore. (Figure 3 & 4)
Caution: The convex surface of the disc must be facing outward at the installer. (Figure 5) Carefully inspect the
disc prior to installation. Make sure the contact surface of the body is clean for the disc to seal. Install the disc seat
on top of the disc center carefully. The disc seat can be installed from either side as it is symmetrical. (Figure 6)
Engage hex wrench flats on burst disc cap with an adjustable/open end wrench. Rotate the cap in a clockwise
direction. Tighten securely. (Figure 7)
PROCEDURE
For Field Replacement and Repair of Burst Disc Assembly (disc exhausted)
1. Using a large adjustable wrench or box open end wrench, engage the hex wrench flats on the burst disc housing.
Firmly, rotate the housing in a counterclockwise direction. Caution: Do not work over the housing during removal.
Remove housing from actuator. Clean all Teflon tape or liquid residue from internal and external threads before
replacement. Wrap Teflon tape in opposite direction to normal thread engagement around the threaded end of
the housing. Wrap securely. If Teflon liquid is used apply generously. Thread housing in actuator. Rotate in a
clockwise direction. Tighten securely. Check burst disc cap for tightness. The burst disc assembly is ready for
pressure service.

Figure 1

Figure 2

page 30

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

SERVICING ARRAY MODEL APHW WIRE CUTTING ACTUATORS


1. Prior to servicing the actuator assembly, it is recommended that this manual be read in its entirety. Should the
service technician have any questions or feel that a certain procedure cannot be performed safely, contact the
factory for assistance.
2. For safety precautions and due to the weight andor size of some actuator assemblies and the presence of pressurized
fluids in the actuator and valve, personnel should be wearing the proper safety equipment such as steel toe shoes,
hard hats, safety goggles and lifting support belts.
3. When moving an actuator assembly or heavy parts, suitable lifting devices such as hoists and a come-a-long should
be used. It is recommended that the weights of the equipment being serviced be obtained from the appropriate gate
valve manufacturers technical bulletins to confirm that any lifting equipment be used is adequate. CAUTION: When
using lifting eyes make sure they are forger single piece design. Engage thread completely before lifting.
4. DO NOT attempt to remove any items from the actuator assembly when it is pressurized. BLEED OFF ALL control
pressure and disconnect the supply lines before performing any service functions. Failure to do so could result
in equipment damage or personal injury.
5. The work area should be clean and free of contaminants such as dirt, sand and metal shavings etc.
6. All grease or lubricants must be free of any contaminants. Any utensils such asbrushes or applicators must also be
free of any foreign particles.
7. All tools used should be clean, in good working order and be the proper tool for the operation to be performed.
8. Keep all elastomers and/or replacement parts in the original storage or shipping packaging until installed.
9. Cleaning must be finished prior to installation or inspection of any new or used component. A suitable fluid
should be used that is compatible with the part being cleaned. Most naphtha based solvents are good for heavy
de-greasing of metallic parts. A solution of warm soap and water is recommended for all non-metallic pieces or
simply wipe with a clean cloth. The use of commercially available aerosol dispensed brake cleaners may be used on
metal parts only. CAUTION: If the part is coated, test the vapor build up if using indoors.
10. All new or used parts must be examined after cleaning for burrs, dings, anomalous marks, cuts, nicks etc prior
to using them.
11. Lightly lubricate all sealing surfaces with suitable grease prior to installing them.
12. When handling any parts that have sealing surfaces, care should be taken not to mar those surfaces.
13. CAUTION: Failure to follow the procedures given in this manual may result in equipment damage, operating
problems and/or personal injury.

page 31

TESTING

page 32

1. The new assembled actuator will be tested per API 6A, latest edition. The following
section is applicable to latest edition 10.16.6.
a. Verify the following that all mechanical lock open devices are removed when proceeding with operational testing
and back seat testing.
b. Hydrostatic testing of actuator, bonnet and gate valve may employ a mechanical override only. NO LOCK CAPS ARE
TO BE USED ON HYDROSTATIC TESTING.
c. Remove the pressure relief device from the actuator. After testing is complete the safety relief device will be
assembled to the actuator. Use a gauge or solid plug as a replacement.
d. In house testing will use hydraulic/nitrogen for functional testing. If problems arise during testing with the actuator,
disassemble. Repair and re-assemble.
e. All testing must be performed by certified assemblers and testers.

PERIODIC MAINTENANCE
The following maintenance schedule is recommended to insure safe and reliable operation of the
Array Model APPM Actuator.

MAINTENANCE OPERATION

Cycle actuator under normal operating conditions.

Monthly

2.

Replace pressure relief device (Burst Disc)


Check for leakage around threads.

Monthly

Inspect Top Shaft

Monthly

4.

Inspect bolts and washers on top and bottom


of actuator

Monthly

5.

Check top shaft packing retainer and retainer ring


in top of cylinder

Monthly

1.

3.

INTERVAL

TROUBLESHOOTING

TROUBLE

Control Pressure in
Actuator Will Not Build

Actuator Will Not Stroke


on a Valve Whether or not
Valve is Pressurized

page 33

PROBABLE CAUSE

REMEDY

Damaged control line

Inspect control line for damage and/or


leaking fittings

Insufficient pressure in
control line

Install gauge at pressure source to


verify desired pressure

Faulty pressure gauge

Verify pressure gauge is correctly


calibrated

Leak around top and/or bottom


of actuator

Replace and/or inspect seal in accordance with assembly

Insufficient pressure in control


line

Verify pressure availability from source.


Consult control pressure information
from the information chart per size
valve application

Bonnet to bonnet stem binding

Consult appropriate maintenance and


operating instructions for bonnet

Valve and/or seats improperly


installed

Remove actuator as instructed per this


manual. Remove bonnet as per bonnet
manufacturers operatinginstructions.
Repair and/or replace valve components
as per valve manufacturers repair manual

Debris in valve body and


actuator vents

Remove actuator as instructed per this


manual.Remove bonnet as per bonnet
manufacturers operating instructions.
Clean debris from valve body

Debris in shaft or housing

Re-inspect housing and spring

Bonnet stem is not fully extende Grasp stem in bonnet and pull to full
extension,properly back seating system
fully extended and seated

Actuator Will Not Attach


to Bonnet Assembly

Bad or wrong threaded on


bonnet stem and down-stop on
bonnet/spring assembly

Check threads on bonnet stem and


down-stop plate for burrs, nicks, dings
and debris. Check size and thread
pattern for proper engagement

Check thread engagement on bonnet


Spring cartridge too long
stem and down-stop. Check for positive
because of bonnet engagement
distance between down-stop and drift
to down-stop
spacers on packing retainer

TROUBLESHOOTING

TROUBLE

Actuator Will Not Stroke


To Full Closed or Fail Safe
Close Position

Actuator House Stops prior to


Alligning with Bonnet Ring

page 34

PROBABLE CAUSE

REMEDY

Gate and seats are improperly


installed causing excessive
friction

Remove actuator as instructed per this


manual. Manuallypush and/or pull bonnet
stem to determine severity of binding. If
severe, remove bonnet and gate and seats,
clean and inspect gate and seats for wear
and abrasion. Replace if necessary.

Excessive seal friction due


to loss of lubrication in
bonnet/valve

Actuate valve several times and lubricate


valve in accordance with manufacturers
maintenance manual

Improper gate to stem


engagement

Remove actuator as instructed per this


manual. Remove bonnet as per bonnet
manufacturers operating instructions.
Check engagement per valve manufacturers
instructions and/or drawings, re-assemble.
This problem only applies to certain valves.

Bonnet ring not threaded down


to positive stop

Check for thread engagement between


stem nut and spring adjusting nut

MODEL APPM PISTON PNEUMATIC ACTUATOR


CONTROL PRESSURE EQUATIONS
page 35

ACTUATOR SPECIFICATIONS
Maximum Operating Pressure:
Test Pressure:
API Material Class:
API Temperature Rating:
API Performance Requirement:
Can be certified for Offshore SSV:

5,000 psi / 345 bars


7,500 psi / 518 bars
BB
P -20 F to 180 F (-29 C to -82 C)
PR-2, Annex F
Yes

BONNET SPECIFICATIONS
Bonnets Available for Valve Brands:
Size Range Available:
Pressure Ranges Available:
API Material Classes Available:



Any Manufacturer (with Current Interface Drawing)


API 6A 113/16" through 71/16"
See Control Pressure Chart
AA,BB,CC (non-NACE)
DD-0,5 / DD-1,5 / DD-NL
EE-0,5 / EE-1,5 / EE-NL
FF-0,5 / FF-1,5 / FF-NL
HH-NL

API Product Specification Levels Available:


API Performance Requirement Available:
API Temperature Ratings Available:
Can be certified for Offshore SSV:

PSL-1, 2 or 3, Annex F
PR-1 or 2
L through X
Yes

LIMITED PRODUCT WARRANTY


The following warranty is exclusive and lieu of all other warranties.
Whether express, implied or statutory, including, but no by way of
limitation, any warranty of merchantability or fitness for any
particular purpose.
Array Products warrants to each original buyer of products
manufactured by Array that such products are free from defects
in material and workmanship under normal use and service for a
period of one (1) year from the date of shipment provided that no
warranty is made with respect to: Any product which has been
repaired or altered in such a way in ARRAYs judgment, as to
affect the product adversely; Any product which has, in ARRAYs
judgment, been subject to negligence, accident or improper
storage; Any product which has not been operated or maintained
in accordance with normal practice and in conformity with
recommendations and public specification of Array.

ARRAYs obligation under this Warranty is limited to use


reasonable efforts to repair, replace or, at its option, refunding
the purchase price. The cost of labor for installing a repair or
replacement product shall be borne by Purchaser. Replacement
parts provided under the terms of this Warranty are warranted for
the remainder of the warranty period of the products upon which
they are installed to the same extent as if such parts were original
components thereof. Warranty services provided there under do
not assume any liability for damages caused by any delays
involving warranty service. For complete specification information,
prices and name, address and telephone number of the ARRAY
representative nearest you, call or write to us at the address below.

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


ARRAY PRODUCTS
4520 E. Chandler Road, Muskogee, Oklahoma 74403
Phone: 918.682.7952 Fax: 918.682.7904 Toll Free: 866.445.1837 www.array.com

2008 Array Holdings, Inc. All specifications and materials are subject to change without notice.