LP BY PASS VALVE202787-88-89-90 - Raigarh - Operation and Maintenance Manual - Par PDF

DOCUMENT COVER SHEET
PROJECT INFORMATION
CUSTOMER NAME : BHEL HEEP – HARDWAR
PROJECT : Raigarh 1, 2, 3 & 4
PROJECT NUMBER : 202787 / 202788 / 202789 / 202790
PURCHASE ORDER : B0V6756
DOCUMENT INFORMATION
DOCUMENT TITLE : Operation and Maintenance Manual
DOCUMENT NUMBER : Raigarh_6560_Operation and Maintenance Manual
DOCUMENT REVISION : A
TAG NUMBER : All
DOCUMENT TYPE : Operation and Maintenance Manual
PURPOSE : Information
IFS DOCUMENT NUMBER : 1013803
REVISION HISTORY
A 05-Dec-12 1st Issue

REV DATE DESCRIPTION
LP BYPASS CONTROL VALVES;
HYDRAULIC POWER UNIT;
OPERATING & MAINTENANCE MANUAL
Plant: Raigarh
Country: India
Supplied by: CCI AG, Switzerland
Date: 08.2012
Order No.: S.O. 104748 P.O. 202787

Order No.: S.O. 104749 P.O. 202788
Order No.: S.O. 104750 P.O. 202789
Order No.: S.O. 104751 P.O. 202790
Record Copy: 6560
CCI AG • Itaslenstrasse 9 • CH-8362 Balterswil • Switzerland

Phone: 0041 (0)52 264 95 00
e-Mail: cciag@ccivalve.ch
Das Urheberrecht an diesem Buch verbleibt bei CCI AG

The Copyright of this book remains with CCI Ltd.
CONTENTS OF THE MANUAL
Manual: Raigarh 6560
Register 1: Revisions & Notes for the User; Safety & Health
Register 2: Erection Instructions
Register 3: Description of Main Components
Register 4: Electrical & Electro-hydraulic Equipment
Register 5: General Maintenance Instructions
Dismantling & Assembly

Register 6.1: Actuators
Register 6:
Register 6.2: CCI AG Valves
Register 6.3: DRAG® Valves
Register 7: Hydraulic Power Unit
Register 8: Electronic Equipment
Register 9: Diagrams, Data Sheets & Dimensional Drawings, Vendor Literature
Sectional Drawings, Top Assembly Drawings, Parts Lists, Ordering

Register 10:
Form for Spare Parts
All Part and Serial Numbers are to be found in the Top Assembly
Drawings.
Das Urheberrecht an diesem Buch verbleibt bei CCI AG

The Copyright of this book remains with CCI Ltd.
REGISTER 1:
REVISIONS & NOTES FOR THE USER
HEALTH AND SAFETY
Contents
REVISIONS 2
NOTES FOR THE USER 3

1 CONTENTS OF MANUAL 3
2 MODIFICATION SERVICE 3
3 ORDERING OF SPARE PARTS 3
4 GENERAL NOTES 3
HEALTH AND SAFETY 5

1 GENERAL SAFETY 5
2 WARRANTY 5
3 SITE HEALTH AND SAFETY INSTRUCTIONS 5
Register 1
Revisions & Notes for the User; Health and Safety Page 1 of 6
REVISIONS
OBSOLETE NEW
Date Reg. Remarks
to be removed to be inserted
08.2012 Final Issue
Register 1
NOTES FOR THE USER
1 Contents of Manual
This manual contains the necessary documents and directions pertaining to all components
specified in our scope of delivery.
It pursues three objectives:
- description of plant components
- operating instructions
- maintenance instructions
2 Modification Service
Justified modifications and additions which may become necessary, will be integrated in our
documents and sent to the client for exchange in his manual.
3 Ordering of Spare Parts

There is an ordering form for spare parts. Please use this form for your orders. When ordering
spare parts the following information is required:
- Book number
- Register & page
- Item & name of the part
If provided, please also indicate the number of the corresponding drawing.
4 General Notes
Only correspondingly trained and instructed professional personnel is permitted to perform
operation and maintenance work at the CCI AG components. This manual does not contain
instructions and references that are part of the professional engineer's training and knowledge.
The same also applies to safety regulations while working with electrical systems. All
applicable regulations of local authorities as well as those of the plant owner must be followed.
Especially the ones concerning accident prevention must be strictly fulfilled. In case of serious
discrepancies with instructions given in this manual, please contact CCI AG.
CCI AG declines any responsibility concerning function and safety of supplied components
and systems, when:
- Operating and maintenance instructions are not followed.
- Spare parts used were not supplied by or no written approval was given by CCI AG.
- Modifications made on components or systems, adding or removal of parts on CCI AG
components, or components and systems used beyond their range of application, without
prior written approval by CCI AG.
- Flow conditions exceeding the design conditions.
Register 1
From the content of this manual no claims can be evaluated, exceeding the contractual
obligations by CCI AG relevant to the customer. Only the contract between CCI AG and the
customer is relevant for guaranty and reliability issues.
CCI AG reserves the right, without notice, to alter or improve the designs or specifications of
the products described herein.
Our Service department is prepared to discuss solutions to any problems concerning the
maintenance and inspection procedures applicable to CCI AG equipment. Please direct all
inquiries to:
CCI AG Phone: +41 (0)52 264 95 00
Itaslenstrasse 9 Email: cciag@ccivalve.ch
CH-8362 Balterswil, SWITZERLAND WEB: www.ccivalve.com
Register 1
HEALTH AND SAFETY
1 General Safety
This section contains general safety information, which must be observed during the
installation commissioning, operation and maintenance of the equipment.
Service engineers and operators must be familiar with all the information in the manual before
starting any maintenance or operating activity.
For reference the manual should always be in reach of the installed equipment.
2 Warranty
When damage caused by non-operating with these instructions causes may void the warranty!
For consequential losses over CCI AG assume no liability!
When property or personal injury caused by improper handling or failure to observe safety
instructions occurs, CCI AG assumes no liability!
In any of the above mentioned cases all warranty claims expire.
3 Site Health and Safety Instructions

Before performing any of the actions detailed within this manual, the "Site Health and Safety
Instructions" are to be read and fully understood.
Whenever the equipment is operated, maintained or used in any way, the procedures detailed
within the Health and Safety Dossier of the manufacturer and any procedures detailed within
these instructions are to be followed.
3.1. Safety Labels and Notes

Special safety instructions, which apply to specific procedures or operations, are indicated in
manuals produced by CCI AG with the use of the following symbols:
3.1.1. Danger Sign with Note
- Warning of the presence of dangerous electrical supplies.
During electrical operation certain parts inevitably carry lethal voltages. To
avoid personal injury and damage to the process system, disconnect the
equipment from all electrical power lines.
3.1.2. Warning Sign with Note

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

drained.
Register 1
3.1.3. Observing Sign with Note
- Comply with these instructions to avoid impact damage.
All repair and maintenance works on actuators must only be carried out by
qualified and trained personnel.
3.1.4. Care or Notice Sign with Statement

- Comply with these instructions to avoid unnecessary delays.
Caution: Hydraulic fluid may escape!
In addition, check for notes and comments on coverage.
Register 1
REGISTER 2:
ERECTION INSTRUCTIONS
Contents
IMPORTANT NOTES ON THE INSTALLATION OF CCI AG / SULZER LOW PRESSURE

BYPASS VALVES 2
1 VALVE ARRANGEMENT 2
2 INLET LINE 2
3 OUTLET LINE 4
4 FORCES AND TORQUES ACTING ON BYPASS VALVES 4
5 ACCESSIBILITY OF VALVES, DISMANTLING 5
6 LAYOUT OF HYDRAULIC SYSTEM 5
7 MEASURES FOR NOISE REDUCTION 5
8 NOTES 6
GENERAL INSTRUCTIONS CONCERNING INSTALLATION OF CCI AG / SULZER VALVES 7

1 TRANSPORTATION AT INSTALLATION SITE 7
2 INSTALLATION 7
3 WELDING 8
4 HEAT TREATMENT 8
5 CLEANLINESS 8
STORAGE INSTRUCTIONS FOR CCI AG / SULZER VALVES AND SYSTEMS 9

1 CCI AG / SULZER PACKING 9
2 PERMISSIBLE CONDITIONS FOR TRANSPORT AND STORAGE 9
3 STORAGE AREA CATEGORIES 9
4 SPECIAL STORAGE INSTRUCTIONS 10
5 TRANSFER OF RISK AND TAKE-OVER 10
UNPACKING INSTRUCTIONS FOR CONTROL & INSTRUMENTATION EQUIPMENT 11
RESISTANCE OF CCI AG / SULZER VALVES AGAINST CHEMICAL CLEANING 12
INSPECTION OF THE VALVES AFTER BOILER BLOWOUT WITH OR WITHOUT PRIOR CHEMICAL
CLEANING 13
1 INSPECTION WITH PRIOR CHEMICAL CLEANING 13
2 BLOWOUT 13
RECOMMENDATIONS FOR PICKLING OF HYDRAULIC PIPES 14

1 GENERAL 14
2 FLUSHING INSTRUCTIONS 14
LIST OF FIGURES REGISTER 2 15
Register 2
Erection Instructions Page 1 of 15
IMPORTANT NOTES ON THE INSTALLATION OF CCI AG / SULZER
LOW PRESSURE BYPASS VALVES
1 Valve Arrangement
We recommend installing the valves in the vertical position, i.e. with the actuator above the
valve. This is the most convenient position for maintenance work. Basically, other
arrangements are possible, but CCI AG should first be consulted.
2 Inlet Line
(Between branch-off from the live steam pipe and the LP-Bypass valve inlet)
The inlet line must be run so that condensate can flow back into the live-steam pipe, thus
avoiding thermal shocks due to the formation of condensate.
Water pockets must be avoided. If this is impossible, such pipe sections must be equipped with
constantly acting draining facilities of adequate capacity and pressure difference.
With a view to avoiding noise and vibration, it is advisable to provide a straight section of
piping 5 to 10 times the internal diameter long, immediately upstream of the valve.
S-bends with two elbows in different planes should be avoided near the inlet of the valve.
If the layout involves a number of bypass valves branching from a common pipe, measures
must be taken to eliminate undesirable pressure oscillations in the inlet lines resulting from
resonance (see Example 1 to 5).
The valves must be pre-heated to a temperature of approx. 50°C (max. 100°C) below live
steam temperature, i.e. if the distance between valve and HRH (hot reheater)-line exceeds
approx. 2m a separate pre-warming line to the valve inlet is required.
The bypass valves ensure good tightness. Therefore, no additional upstream isolating valve is
needed.
If an isolating valve is nonetheless fitted, it must be ensured that the bypass valve is held at the
correct pre-warmed temperature to keep it at operating readiness.
Register 2
2.1. Layout Examples
(LS = Live Steam Pipe)
Fig. 2-01: Examples of Poor Layouts
Fig. 2-02: Examples of Good Layouts
Register 2
3 Outlet Line
Outlet lines that rise downstream of the valve must be avoided. With rising lines there is a
danger of water pockets forming due to condensate collecting. When the bypass valve trips
open, heavy water hammer may occur and cause damage.
If rising lines are unavoidable, they must be fitted with open drains. In case an open drain is
not possible, reliable constantly-acting drain devices must be provided, a small one for
accumulations of condensate, a large one that is integrated into the start-up procedures.
If there are two or more parallel bypass valves, each outlet line must have its own drain
facilities.
GOOD POOR
Bypass
outlet pipe
Drain
Fig. 2-03: Bypass Outlet Pipe; Good and Poor

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

Valves must be freely hung in the pipe work. Under no circumstances may they form fixed
points. From the valve manufacturer's viewpoint, a piping system is properly designed if the
valve body is more rigid than the piping connected to it, i.e. the section modulus of the valve
nozzles must be greater than that of the connected piping. If this condition is fulfilled, the
valve body can transmit forces and moments without becoming deformed and there are no
unacceptable effects which might impair the operability of the valve.
When checking section modulus figures, allowance must be made for any differences in the
materials of valve nozzles and the piping.
The admissible section modulus figures are shown on the dimensional sketches.
Register 2
If for any reason the piping has higher section modulus figures than the valve nozzles, we must
be informed of the forces and moments that occur. We will then check the valve body on the
basis of these figures. If the results are unacceptable, the piping system will have to be made
more flexible.
5 Accessibility of Valves, Dismantling

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

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

When noise reduction measures are planned, it should be considered that in most applications
the bypass is a start-up/shut-down device with relatively short operating periods. Most
regulations accept higher noise levels for short operation periods. The number of expected
start-ups/shut-downs should also be considered.
If the steam velocity in the outlet nozzle is lower than 200 m/sec., we recommend the
following arrangement:
Register 2
Fit a straight, thick-walled pipe section with a length of at least 5 x I.D. (but min. 2 m),
immediately downstream of the valve, the internal diameter coinciding as closely as possible
with the valve outlet nozzle internal diameter as shown in the dimensional sketch. If an elbow
follows this straight pipe section, we recommend flaring the line downstream of the straight
section to provide a conical transition section and fitting an elbow with enlarged diameter to
reduce steam velocity. If reasons of space make the foregoing solution impossible, the straight
pipe section should nonetheless be retained followed by the elbow with the same internal
diameter as the pipe, but with a conical section leading to a larger diameter then being fitted
downstream of the elbow (see Example 7 to 9).
If the velocity is higher than 200 m/sec. then a multi-hole orifice should be installed to limit
the velocity in the outlet nozzle to 150-200 m/sec.
A further improvement is possible by replacing the thermal insulation on the outlet piping by
combined thermal/noise insulation.
- min. 100 mm mineral fiber (80-100 kg/m3), e.g. pressed shells
- an outer shell of 1 mm steel plate
Noise bridges between piping and outer shell must be avoided.
The solution shown in Example 7 is better than that in Example 8; but Example 8 is better than
that in Example 9.
Example 7 Example 8 Example 9
Fig. 2-04: Noise Bridges Between Piping and Outer Shell
8 Notes
We recommend that you send us your preliminary layout drawings prior to finalizing the
design. We shall be happy to examine them in the light of our experience and make any
recommendations which may seem necessary.
Register 2
GENERAL INSTRUCTIONS CONCERNING INSTALLATION OF CCI AG / SULZER
VALVES
1 Transportation at Installation Site

The valves shall be transported from the storage place to the place of installation using utmost
care. In order to avoid any damage, they shall, whenever possible, not be unpacked until
shortly before they are fitted.
Serious injuries may occur if valves and components are not handled
properly. Therefore, suitable lifting equipment must be properly used and
attached, i. e. carefully wrap rope slings around valve yoke or actuator, or
use the lifting points provided.
All applicable codes, regulations and industrial practices for handling loads must be followed.
These include, but are not limited to, the following precautions:
a) Rope slings shall be free of kinks and twists.
b) Position lifting hook above the load such that the load does not swing when lifting.
c) Care shall be taken that the load is well secured and balanced.
d) The operator shall ensure that rope slings are not handled on the hoist hook without his
knowledge.
e) Carrying loads above people is not permitted.
2 Installation
The valves are delivered with the stem in the closed position, and they shall be welded-in in
this condition. While welding the valve into the piping, pay close attention to the flow
direction as marked by an arrow on the valve body.
- When fitting the valves, it is imperative that they are welded into the piping free of stress.
The protection plugs on the valve nozzles shall not be removed until just before fitting and
the machined surfaces of the welding joints shall not be damaged. The valve shall only be
lifted using the lifting points provided.
If no such lifting points are provided, the valve shall under no circumstances be lifted by
attaching any of its valve trim to the lifting device. Only the valve body may be attached to the
lifting device. Under no circumstances it is permitted to attach additional fix points for the
piping system, for additional loads, or for tack welding, to the valves.
The valves and actuators must be accessible for maintenance work.
When lifting and handling loads, ensure that accessories and lines, as well
as sealing surfaces of valves and flanges, are not damaged.
Register 2
3 Welding
3.1. Welding the Valve in Piping Lines

The instructions concerning welding and heat-treatment shall be furnished by the supplier of
the piping, or by the company carrying out the welding. These instructions must observe for
welding the valves into the piping. The valve shall be welded-in with the stem in the "closed"
position.
Do not use valve stems or piston rods of actuators for grounding (earthing)
during welding operations.
3.2. Welding the Spray Water Nozzles
Before welding of the valves into the piping the water connection spray
nozzles follow the instructions listed below.
If the distance from the pipe welding end to the spray nozzles is less than 300 mm, the nozzles
have to be removed for the welding and post weld heat treatment so that the heat treatment
does not affect the spring strength.
If the distance is more than 300 mm and the nozzles are not removed, then using insulation
you have to make sure that the maximum allowable temperature at the spray nozzle housing of
250 °C is not exceeded during the post weld heat treatment.
4 Heat Treatment
If heat-treatment of welds is required, care must be taken during the annealing process that the
valve is not subjected to any inadmissibly high temperatures (maximum to the annealing
temperature as indicated in annealing instruction for the material used). The valve body shall
not be insulated (heat transfer). The internal parts of the valve must not be removed during the
annealing process.
5 Cleanliness
Absolute cleanliness must be observed throughout the installation operation. Actuator and
valve assembly shall be covered to prevent dirt, emery dust or other foreign matter from
getting into the valve and actuator. In the event of long periods of time between fitting and
commissioning (without preservation of the installation), it is recommended that all parts are
treated with an anti-corrosive agent.
In the case of hydraulic actuators, make sure that the drillings for the hydraulic fluid are
always completely closed. Where provided, the control units, solenoid valves and safety
devices shall not be fitted until just before commissioning of the installation.
Register 2
STORAGE INSTRUCTIONS FOR CCI AG / SULZER VALVES AND SYSTEMS
The equipment supplied should be stored in clean and dry conditions, protected against
mechanical damage, and kept in the CCI AG / SULZER original packing in closed rooms.
1 CCI AG / SULZER Packing

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

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

The storage areas must be protected against fire. Smoke can be harmful to the goods. The
storage areas should be accessible to authorized personnel only.
A closed room is understood as being a room that completely protects the stored material
against any weather effects, exposure to sunlight and against dirt and dust. The material must
not be subjected to extreme humidity or dew. Roofs and walls made of plastic or tarpaulin are
not accepted as closed rooms.
Register 2
4 Special Storage Instructions
4.1. Valves
If a storage period is longer than 6 months, the CCI AG / SULZER can supply the valve gland
packings separately at the client's request. In such cases the valves should be checked before
installation.
4.2. Actuators
Electric actuators must be completely filled with oil as soon as it is certain that they will be
stored for more than one year.
- The vent filters must be replaced by locking screws.
- Hydraulic actuators and the associated oil supply equipment must be checked by an expert
authorized by CCI AG / SULZER after one year of storage.
4.3. Measuring Transformers and Electronic Equipment

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

Special inspection intervals for spare parts must be agreed upon between Purchaser and CCI
AG / SULZER.
5 Transfer of Risk and Take-over

The Purchaser bears all risks of the goods in accordance with the Contract, i.e. CIF, FOB, etc.
as defined under INCOTERMS. If dispatch is delayed or prevented by circumstances beyond
CCI AG / SULZER's control, the goods will be stored in the CCI AG / SULZER Works at the
Purchaser's expense and risk.
If the goods are stored on site the client bears all risks. He shall also bear the costs for any
damage, theft or destruction caused by events beyond CCI AG / SULZER's control such as
water, fire, etc. It is up to the Purchaser to take out insurance against damage of any kind. Even
if insurance cover is arranged by CCI AG / SULZER, it shall be taken out on behalf of the
Purchaser and at his expense and risk.
Register 2
UNPACKING INSTRUCTIONS FOR CONTROL & INSTRUMENTATION EQUIPMENT
Equipment for control and instrumentation is generally high-technology material which on no

account shall be exposed to normal weather conditions (see storage instructions). Moisture,
especially in the vicinity of the sea, and dust can result in irreparable damage.
For the most part, the equipment is vacuum-packed with desiccants. We strongly recommend
that the equipment be left in its original transparent vacuum packing, unopened, until
installation work is started. If this package is opened for any reason, the equipment must then
be re-packed in a new vacuum pack, and new desiccant must be used. A written record must be
made of the opening and re-packing operations.
All plug-in electronic modules are removed from the control cubicle for transportation and
delivered in special polystyrene shipping cases. A package is supplied for each chassis frame
occupied in the cubicle. Inside these shipping cases the electronic modules are arranged
according to their layout in the chassis frame.
The electronic modules must only be inserted in the cubicles, i.e. in the
chassis frames, by the commissioning engineer after an assembly test has
been carried out
The electronic modules belonging to each cubicle are vacuum-packed in the polystyrene
shipping case. Each individual cubicle is also vacuum-packed. The cubicle and the electronic
modules are packed and shipped together in one crate.
When assembly work is started, the electronics room must be dust-free, dry and lockable. The
crates are then opened, the electronic modules in their original package are stored in a suitable
store, and the side walls of the crate are removed in the electronics room so that the cubicle can
easily be erected with the help of the jack rings supplied. All 4 jack rings must be used to
ensure that the cubicle does not tilt.
Damage to the packages or visible shipping damage to the cubicles or equipment must be
reported immediately in writing.
Register 2
RESISTANCE OF CCI AG / SULZER VALVES AGAINST CHEMICAL CLEANING
Usually pickling-proof materials are used for the valves. Yet it must be noted that the 13%
chrome steels are pickle-proof only to some degree when certain pickling methods are used.
For this reason the materials used must be submitted to the pickling company for judgment.
The necessary information is contained in sectional drawings and relevant material lists.
The pickling company decides whether the materials used are pickling-proof.
After pickling the gland packing must always be replaced. Since they soak up pickling liquid
they might later cause corrosion on the valve stem.
Register 2
INSPECTION OF THE VALVES AFTER BOILER BLOWOUT WITH OR WITHOUT
PRIOR CHEMICAL CLEANING
1 Inspection with Prior Chemical Cleaning

If the boiler has been chemically cleaned, then the pressure seals and gland packings of the
affected valves must be replaced, in order to prevent corrosion due to residual amounts of acid
left in the packages.
2 Blowout
During the boiler blowout, particles of dirt in the blowout steam can cause damage to valve
seats and stems. Therefore special internals should be used for blowout.
Furthermore, the inside of the valve body is to be cleaned to remove any foreign particles.
Register 2
RECOMMENDATIONS FOR PICKLING OF HYDRAULIC PIPES
1 General
If pipes are bent in hot condition then they have to be pickled in sections afterwards. It is
advantageous to dismantle the pipes for pickling and, if possible, to have it done by a company
specialized in pickling.
If the pipes are installed in such a way that they cannot be taken apart, the work must be
carried out on site. This, however, requires considerably more material and time.
To prevent renewed contamination, erection should be carried out

immediately after pickling.
Pickling is not required if:

- pipes used have been correctly preserved
- cleanliness has been strictly observed
- in case of welding, pipe inner bores have been continuously flushed with pressurized inert
gas
Pickling is a chemical method of cleaning and is carried out using
saponifying alkalis, organic solvents and acids. Special agents (inhibitors)
are used to delay the corrosive effect of the acids without impairing the
cleaning capability.
In order to protect the materials against uncontrolled acid corrosion, certain flow velocities of
pickling medium must be maintained. Therefore, pickling is limited to the pipes only. But in
any case, the hydraulic fluid tank, valves and hoses must either be dismantled or bypassed. The
subsequent flushing, however, is intended to clean the entire system, i.e. also the tank and
hoses.
2 Flushing Instructions
See corresponding document: "Commissioning of Hydraulic Power Unit HV and Piping".
Register 2
LIST OF FIGURES REGISTER 2
FIG. 2-01: EXAMPLES OF POOR LAYOUTS 3

FIG. 2-02: EXAMPLES OF GOOD LAYOUTS 3
FIG. 2-03: BYPASS OUTLET PIPE; GOOD AND POOR 4
FIG. 2-04: NOISE BRIDGES BETWEEN PIPING AND OUTER SHELL 6
Register 2
REGISTER 3:
DESCRIPTION OF MAIN CONTROL COMPONENTS
Contents
ELECTRO-HYDRAULIC ACTUATOR SYSTEM WITH PROPORTIONAL VALVE 2

1 PURPOSE 2
2 DESIGN AND OPERATION 2
3 ELECTRO-HYDRAULIC ACTUATOR SYSTEM (OPEN / CLOSE CONTROL) APL 8
4 ELECTRO-HYDRAULIC ACTUATOR SYSTEM (OPEN / CLOSE CONTROL) APLE OR 4/3WEDZ 9
5 ELECTRO-HYDRAULIC ACTUATOR SYSTEM (CONTROL WITH PROPORTIONAL VALVE) 10
ACTUATORS ASM AND GHZ CLASS 11

1 PURPOSE 11
2 DESIGN AND OPERATION 11
3 ACTUATOR TYPES (ASM OR ASMF AND GHZ OR GHZF) 12
SINGLE ACTION CONTROL UNIT (SACU) 13

1 GENERAL DESCRIPTION 13
2 FUNCTION 13
PV CONTROL UNITS 14

1 GENERAL SYSTEM DESCRIPTION 14
2 BLOCKING FUNCTION 14
3 POSITIONING FUNCTION 14
4 MEASURING CONNECTIONS 14
5 ERECTION AND COMMISSIONING 14
6 REPAIRS 15
FEEDBACK TRANSMITTER R – SG 16 + 4K 16
POSITION TRANSMITTER SG 16 17

1 APPLICATION 17
2 FUNCTION 17
3 TECHNICAL DATA 18
4 APPLICATION NOTE 19
LIST OF TABLES REGISTER 3 21
Register 3
Description of Main Control Components Page 1 of 21
ELECTRO-HYDRAULIC ACTUATOR SYSTEM WITH PROPORTIONAL VALVE
1 Purpose
The CCI AG electro-hydraulic actuator system is used in connection with control valves,
safety valves, etc. The electro-hydraulic actuator combines high positioning forces with a fast
positioning speed and a high positioning accuracy.
In combined safety / bypass stations the additional cost of the safety control system is minimal.
Furthermore, it is possible to have stored actuating power with hydraulic fluid accumulators
which are available even when a power failure occurs.
If the plant already has a central hydraulic power supply unit, the CCI AG hydraulic actuating
systems can be added at a reasonable cost.
2 Design and Operation
2.1. Summary
The electro-hydraulic actuating system is designed as a modular system. It consists of the
following components:
Actuator ASM or GHZ required in every case
only if there is not already a hydraulic power
Hydraulic power unit
unit
Control unit PV
Positioning unit PVR
Stepping control unit APL or 4/3WEDz
} PV and APL or 4/3WEDz is required in
every case
Safety control system SSB as required

Safety bypass system SBE as required
Fig. 3-01: Electro-hydraulic Actuating System
Register 3
Each actuator requires either a control unit or a stepping control unit. In addition, up to three
additional control units per valve can be fitted as required.
Fig. 3-02: Actuators with Control Units
2.2. Actuator ASM or GHZ

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

The hydraulic power unit supplies the hydraulic energy necessary for the actuators. A single
unit can supply several actuators. The main component of the hydraulic power unit is the pump
which pumps the hydraulic fluid from a tank into a hydraulic accumulator. The unit also has
control and safety equipment to guarantee the supply of hydraulic fluid from the accumulator.
The purpose of the accumulator is to cover load peaks. A pressure-reducing valve keeps the
system pressure constant within narrow limits.
Register 3
The hydraulic power units and accumulators are transported and delivered
for safety reasons without nitrogen charging pressure.
Before start-up all hydraulic accumulators in the system have to be filled
with nitrogen to the nominal charging pressure.
The nominal charging pressure is to be taken from the data sheet.
Fig. 3-03: Hydraulic Power Unit
2.4. Control Unit PV

The control unit converts the electrical signals from the control system into a flow of hydraulic
fluid. It controls the intake and discharge of hydraulic fluid to and from the piston chambers of
the actuator in a continuous control mode, thus permitting very precise positioning of the
actuator. With high response sensitivity and stability, stroking times of less than three seconds
can be achieved without difficulty.
The blocking function ensures that the actuator is held drift-free in its position during manual
mode or if a malfunction occurs.
Furthermore, the blocking function is assured by two pilot-controlled check valves. If power
failure or loss of hydraulic pressure occurs, the check valves close the bores to the actuator.
The control unit solenoid is controlled by a current signal which is proportional to the
deviation of the set value from the actual value. With a higher current on the solenoids, the
flow through the directional valve is increased.
Fig. 3-04: Control Unit PV
Register 3
2.5. Stepping Control Unit APL / APLE and 4/3WEDz
The stepping control unit is the simplest way of controlling an actuator. It provides only a step-
control mode and is used for pure on/off operation.
The central part of the stepping control units is a 4/3-way valve operated by two solenoids. A
system of throttling orifices and releasable check valves makes it possible to set the
positioning speed independently in either direction and ensures that the actuator is held in its
position without drifting.
Fig. 3-05: Stepping Control Unit APL, APLE and 4/3WEDz
2.6. Open / Close Control Unit 4/2WEDz

The control unit is the simplest way of controlling an actuator. It provides only a step-control
mode and is used for pure on/off operation.
The central part of the stepping control units is a 4/2-way valve operated by one solenoid.
Fig. 3-06: Open / Close Unit 4/2WEDz
Register 3
2.7. Safety Control System SSB
The safety control system ensures that even if the central power supply fails, the actuator can
be reliably positioned in a pre-determined end position if required. The energy necessary for
this is taken from an additional hydraulic accumulator with a storage capacity sufficient for
one or more strokes, depending on the requirements.
The safety control system is mounted directly onto the actuator and functions as main control.
The SSB can be used either as single or multiple-redundant version. It consists essentially of
two releasable check valves, which, under normal operation, keep the pressure line from the
accumulator to the actuator and the return line to the tank closed. When in use, a solenoid-
operated 3/2-way valve opens the check valves. The additional hydraulic accumulator, which
is not used during normal operation, is kept fully charged by the central hydraulic supply unit.
It is installed in the immediate vicinity of the actuator and connected to the system with a
special connecting block, which can be equipped with a monitoring pressure gauge or pressure
switch.
Fig. 3-07: Safety Control System SSB
Register 3
2.8. Safety Bypass System SBE
The safety bypass system allows the valve to open without any external energy source. Only
the forces exerted by the medium (usually steam) on the valve stem are utilized. This system is
used primarily in connection with HP bypass stations and with actuator-operated safety valves
of the MSV or HSV type.
Fig. 3-08: Safety Bypass System SBE

The safety bypass system is nearly always arranged redundantly to increase system reliability.
Three identical safety bypass blocks are mounted directly onto the actuator. Each consists of a
pilot valve and a main valve. If the solenoid pilot valve is de-energized, the system
automatically opens a bypass line between the upper and lower piston chambers of the
actuator. As a result, the valve stem is moved to its open position by the force exerted on the
valve stem by the medium.
Register 3
3 Electro-hydraulic Actuator System (Open / Close Control) APL
1 Hydraulic power unit 5 Position transmitter

2 Stepping control unit APL 6 Position controller
3 Actuator 7 Connection for additional actuators
4 Control valve
P Pressure line T Return line
Fig. 3-09: Electro-hydraulic Actuator System (Open / Close Control)
Register 3
4 Electro-hydraulic Actuator System (Open / Close Control) APLE or 4/3WEDz

2 Stepping control unit APLE or 4/3We 6 Position controller
4 Control valve
Fig. 3-10: Electro-hydraulic Actuator System (Open / Close Control)
Register 3
5 Electro-hydraulic Actuator System (Control with Proportional Valve)

2 Proportional valve (incl. blocking function) 6 Position controller
4 Control valve
Fig. 3-11: Electro-hydraulic Actuator System (Control with Proportional Valve)
Register 3
ACTUATORS ASM AND GHZ CLASS
1 Purpose
Actuators are part of the CCI AG electro-hydraulic actuating system. Together with the "yoke"
that constitutes the mechanical connection to the valve, they form the valve drive.
ASM and GHZ actuators are manufactured in a variety of sizes and designs. They can provide
actuating forces of up to 1200 kN at high actuating speeds over wide stroke ranges.
2 Design and Operation

ASM actuators are double-acting hydraulic cylinders. They feature highly effective internal
and external sealing and wear-free bearing arrangements of their moving parts.
The actuator piston rod is operated by the controlled supply and discharge of hydraulic fluid to
and from the upper and lower actuator piston chambers.
The coupling, which is easily accessible through the large openings in the yoke, transfers the
actuating force from the actuator spindle to the valve stem. A mechanical position indicator is
provided on a stroke scale.
In addition to a position transmitter (RSG), up to four control units can be mounted directly on
the actuator; these can have different functions, or the same functions for enhanced system
safety.
Depending on the application, ASM actuators are also available with opposing piston rod for
equal acting areas and integral spring. The actuator stroke can be limited with spacer rings.
Register 3
3 Actuator Types (ASM or ASMF and GHZ or GHZF)
Depending on the type of hydraulic fluid, mineral oil or fire resistant fluid / phosphate ester
fluid (e.g. "Fyrquel") to be used in operation, there are different types of actuator. For
operation with mineral oil types ASM / GHZ are used and types ASMF / GHZF are used for
fire resistant fluids / phosphate ester fluids.
Actuators operated with fire resistant fluids / phosphate ester fluids must be equipped with
special seals (e.g. Viton or FPM O-rings). The design of the piston rod guide is another
difference between the two actuator types.
Fig. 3-12: Actuators with Control Units
Register 3
SINGLE ACTION CONTROL UNIT (SACU)
1 General Description
The unit is designed to operate a single acting cylinder with a spring in closing direction.
The unit has a solenoid valve for open and close and two pilot valves in series for the fail-close
function.
2 Function
If both pilot valves 13 are energized, the 2/2 way cartridge valve 02 is closed and the pressure
connection of the solenoid valve 21 pressurized. The actuator remains in the closed position.
Energizing solenoid valve 21 opens releasable check valve 01 and the pressure flow enters the
bottom of the cylinder and opens the steam valve. De - energizing the solenoid valve 21 closes
the releasable check - valve 01 and the spring moves the steam valve in to the closed position.
The fluid leaves the bottom of the cylinder and flows through check valve 10, solenoid valve
21 to the top of the cylinder.
2.1. Fail Close Function

When the pilot valves 13 and solenoid valve 21 are energized and the steam valve is open, de-
energizing one of the pilot valves 13 opens the 2/2 way cartridge valve 02, and the pressure to
the solenoid valve 21 decreases to zero, which closes the releasable check valve 01. The spring
presses the fluid from the bottom through the 2/2 way cartridge valve 02 to the top of the
cylinder.
01 Check-valve 13 3/2-Way seat-valve NG4/G24

02 2/2-Way valve NG16 21 3/2-Way seat-valve NG4/G24
10 Check-valve
P Pressure line T Return pipe to the tank
Fig. 3-13: Control Unit SACU
Register 3
PV CONTROL UNITS
1 General System Description

The control unit serves for the positioning of the cylinder. With the blocking system the
cylinder, if necessary, can be held over longer time in position.
2 Blocking Function
The blocking function is done by two releasable check valves and one 3/2-way valve. By
energizing the 3/2-way valve, the two check valves are opened hydraulically and permit oil to
flow freely to and from the cylinder through the A and B connections. When the 3/2-way valve
is de-energized, the check valves close and the actuator is blocked in its momentary position.
The 3/2-way valve has an emergency spring-centered manual operation feature, which allows
manual operation during a power failure.
3 Positioning Function
The positioning function is done using a proportional 4/3-way valve. This valve converts an
electric signal into a proportional hydraulic signal. This valve is a pure positioning element and
is only able to function with the corresponding amplifying and controlling electronics.
Parameter adjustments of this valve are only possible electronically. The proportional valve
has spring-centered emergency manual operation which allows manual switching if a power
failure occurs.
4 Measuring Connections
Measuring connections are installed in the hydraulic lines A and B to the upper and lower
cylinder chambers. This allows pressure measurements during operation.
5 Erection and Commissioning

Hydraulic valves are functional units which are precision-manufactured. If the necessary
cleanliness is observed during erection, commissioning and operation, the hydraulic valves
ensure perfect function. Because of the mechanical demands and ageing, the hydraulic fluid
must be checked for quality and purity at regular intervals.
The installed filters must be replaced or cleaned in accordance with the instructions. When
replenishing or replacing hydraulic fluids, it should be noted that the hydraulic fluid as
delivered is usually not directly suitable for use in a hydraulic system, because of the solid
particle content. The necessary cleanliness of the fluid can not be guaranteed due to the, often
very long, transportation channels from manufacturer to user. The new hydraulic fluid, either
being replenished or replaced, must therefore be added through the filter on the power unit.
With regard to the fineness of the filling filter, it must be at least as fine as the filter used in
operation in the plant. It is better to use an even finer filter.
To ensure complete sealing with the O-ring, the connecting surfaces between actuator-cylinder
and the control unit must be absolutely clean. On the control units, the cover plates are to be
removed from the connections. Prior to mounting, make sure that the O-rings are correctly
positioned in their grooves. The block can now be bolted firmly to the cylinder, whereby the
bolts must be tightened, alternating diagonally, with the specified torque.
Register 3
When the complete hydraulic system functions as expected, the system must be vented
thoroughly. Thereby it attains the necessary rigidity to provide the required position accuracy.
6 Repairs
Plant operators are advised not to attempt any repair work other than replacing seals and
gaskets on the control components.
A repair by the plant operator one should advise against, if this is to go beyond a seal exchange
at the elements.
This is not to be understood in such a way that our devices would be so sensitively, trouble-
prone or complicated that these work cannot be settled by a mechanic. Rather it is important
that the hydraulic elements are tested and measured the test stand, so that a perfect function
can be guaranteed after repair by the manufacturer.
We generally recommend with plant repairs the exchange of the complete components.
30 Check valve
40 3/2-way solenoid valve
50 Proportional solenoid valve
Fig. 3-14: PV Control Units
Register 3
FEEDBACK TRANSMITTER R – SG 16 + 4K
The feedback transmitter R - SG 16 is for valves with Open/Close function and is produced in
different versions:
- R-SG 16 + 4K Position transmitter and 4 limit switches
- R - 4K only 4 limit switches
The feedback transmitter R-SG 16 + 4K is for control valves. The position transmitter SG 16
measures the valve position and transmits the position to the position controller. The position
controller compares the valve position with the demand position and moves the valve
according the deviation. The limit switches are not used for positioning but may be used for
indicating valve positions.
Fig. 3-15: Feedback Transmitter R – SG 16 + 4K
Register 3
POSITION TRANSMITTER SG 16
1 Application
The SG 16 is a position transmitter using a

magneto-resistive sensor to detect the angular
position. The solid and compact design
assures high resistance to climatic and
mechanical influences as well as electrical
interference. It is simple to install and to
calibrate.
The SG 16 position transmitter converts a
mechanical position (angle of rotation) into an
analog electrical signal for rotation angles
within 30° to 360°.
2 Function
Signal acquisition is processed by an integrated hall-sensor converting the changes in the field
of a permanent magnet into a digital encoded signal. The magnet is connected to the driving
shaft. Finally a digital/analog interface is converting the information proportionally to the
angle into a current signal of 4 … 20 mA.
The current interface is designed for 2-wire operation of the transmitter. The output signal can
be set by membrane keys to any angular range. The applicable extend of angular range is 330°
(saw tooth progression). By the means of a jumper the sense of rotation can be varied
according to the users requirements. The sensor is equipped with a four-pole plug-in screw
type terminal for the electrical connections.
Fig. 3-16: Connection Diagram SG 16
Register 3
3 Technical Data
Tab. 3-01: Mechanical Specifications SG 16
Housing material Saltwater-proof Aluminum

Housing protection IP 65
Terminal protection IP 20
Shaft material Stainless steel
Shaft bearing Ball bearing
Angular range 30° … 360°
Operating temp. range -25° C … +80° C
-25° … +80°C
Stability referred to full rotation angle (e.g. 70°):
±1,0 % FSR
Shock 50g, 6ms
Vibration 10g, 5-200 Hz
EMC Performance EN 50 082-2
EN 61000-6-2
Transient emission
EN 61000-6-3
Weight approx. 450 g
Tab. 3-02: Electrical Specifications SG 16
Signal output 4 … 20 mA; 2-wire system

Pre-adjustment 0 … 140°
Error output current 22.1 mA
Max. burden 500 Ω
Time constant on power-up approx. 20 ms
Signal adjustment via membrane keys
Adjustment sense of rotation via jumper
Supply voltage 18…33 VDC
12bit / FSR *)
Resolution *)
FSR = -Full Scale Range
Linearity ±0.5 % FSR

Test voltage 500 VAC
Electrical connection via plug-in terminals
Valid data 0.8 s after switching-on
Register 3
4 Application Note
The cable of the position transmitter should be twisted and single-shielded. The cable screen
should be connected with the source (conn. diagr.)
The SG16 replaces all types of SG (SG 10 … 15). The application on systems like AV5 or
AV6 may involve a signal recalibration of Uo and ΔU and a wiring modification to the power
supply of 24 VDC. If used on a system prior to AV5 please contact us.
4.1. Dimensions and Characteristics
Fig. 3-17: SG 16 Dimensions
Fig. 3-18: SG 16 Characteristics
Register 3
4.2. Ordering Information
- SG 16 Art. Nr. 103.196.160.200
4.3. Setting Instructions

Factory-provided pre-adjustment of the magnetic rotary encoder is as follows:
- Signal output: 4 …20 mA
- Angular range: 0…140°
- Sense of rotation: clockwise (jumpered)
The sensor is calibrated in the following way (after mech. and el. connections are correctly
established):
1. Adjusting the sense of rotation (Unplug to modify!):
Connection of terminal 3/4 open: counter clockwise.
Connection of terminal 3/4 jumpered: clockwise.
2. Setting of the initial position (0 % = 4 mA):
Move valve to "Closed" position. Push button "0 %" for a time of 0.5 … 1 s.
3. Setting of the final position (100 % = 20 mA):
Move valve to "Opened" position. Push button "100 %" for a time of 0.5 … 1 s.
4.4. Important Information

1. Programming order (0 %; 100 %) has to be kept.
2. In case of pushing a button too long or too short (>1 s or <0.5 s) during a setting operation
the setting is not stored.
Register 3
FIG. 3-01: ELECTRO-HYDRAULIC ACTUATING SYSTEM 2

FIG. 3-02: ACTUATORS WITH CONTROL UNITS 3
FIG. 3-03: HYDRAULIC POWER UNIT 4
FIG. 3-04: CONTROL UNIT PV 4
FIG. 3-05: STEPPING CONTROL UNIT APL, APLE AND 4/3WEDZ 5
FIG. 3-06: OPEN / CLOSE UNIT 4/2WEDZ 5
FIG. 3-07: SAFETY CONTROL SYSTEM SSB 6
FIG. 3-08: SAFETY BYPASS SYSTEM SBE 7
FIG. 3-09: ELECTRO-HYDRAULIC ACTUATOR SYSTEM (OPEN / CLOSE CONTROL) 8
FIG. 3-10: ELECTRO-HYDRAULIC ACTUATOR SYSTEM (OPEN / CLOSE CONTROL) 9
FIG. 3-11: ELECTRO-HYDRAULIC ACTUATOR SYSTEM (CONTROL WITH PROPORTIONAL
VALVE) 10
FIG. 3-12: ACTUATORS WITH CONTROL UNITS 12
FIG. 3-13: CONTROL UNIT SACU 13
FIG. 3-14: PV CONTROL UNITS 15
FIG. 3-15: FEEDBACK TRANSMITTER R – SG 16 + 4K 16
FIG. 3-16: CONNECTION DIAGRAM SG 16 17
FIG. 3-17: SG 16 DIMENSIONS 19
FIG. 3-18: SG 16 CHARACTERISTICS 19
LIST OF TABLES REGISTER 3
TAB. 3-01: MECHANICAL SPECIFICATIONS SG 16 18

TAB. 3-02: ELECTRICAL SPECIFICATIONS SG 16 18
Register 3
REGISTER 4:
ELECTRICAL & ELECTRO-HYDRAULIC COMPONENTS
Contents
CONTROL UNIT PV 6K 3
CONTROL UNIT PV 8 4
POSITION TRANSMITTER R - SG 16 + 4K(G) 5
POSITION TRANSMITTER R - 4K(G) (SG 16) 6
For corresponding Function Descriptions, Connection and Wiring

Diagrams check the appropriate Register.
Register 4
Electrical & Electro-hydraulic Components Page 1 of 7
Item # Part Name Item # Part Name

001 Manifold 013 3 3/2-Way seat-valve NG4/G24
002 2 EO Screw plugs M18 x 1.5-ED 014 4 Cyl.-screw M8 x 100
003 5 Expander KOENIG 015 4 Spring washer ø8.4 x 14
005 Integration check valve 016 2 O-Ring ø25.07 x 2.62
006 Integration check valve 017 2 Protecting plate
007 EO Screw plugs R3/4-ED 018 4 Nut M8
009 2 EO Screw XGE 25-SM-ED 019 EO Screw plugs R3/8-ED
010 2/2-Way valve NG16 020 2 EO Screw plugs XRED 25/20-S
011 Cover 021 Throttle screw M5 x 1
012 Check-valve
Fig. 4-01: Single Action Control Unit (SACU)
Register 4
CONTROL UNIT PV 6K

10 1 Distributor plate NG6 60 3 Screws M5 x 45
Screw coupling to mini-measuring
20 2 70 4 Screws M5 x 50
device 1620 / M14 x 1.5 ED
30 2 Check valve 90 4 Screws M6 x 60
40 1 3/2-way solenoid valve 110 2 O-ring ø25.07 x 2.62
50 1 Proportional solenoid valve NG6, 130 2 Connections for P & T
Seal set, including the seals of the items 30, 40, 50, 110 (these items are not
290 1
available separately)
Fig. 4-02: Control Unit PV 6k
Register 4
CONTROL UNIT PV 8
Drawings: 103.227.861.500 / 103.227.862.500

10 1 Distributor plate NG 8 60 3 Screws M5 x 45
Screw coupling to Mini-measuring
20 2 70 4 Screws M6 x 65
system 1620/ M14 x 1.5 ED
Check valves SUN Cvev xev,
30 2 90 4 Screws M8 x 80
Wandfluh
3/2-way poppet valve BM32041a,
40 1 110 2 O-Rings ø25.07 x 2.62, Viton
Wandfluh
Proportional directional control valve, Screw connector GE20-SM-ED-
50 1 130 2
NG 10 APWS4D101, Wandfluh Viton
Seal set, including the seals of the items 30, 40, 50, 110 (these items are not
290 1
available separately)
Fig. 4-03: Control Unit PV 8
Register 4
POSITION TRANSMITTER R - SG 16 + 4K(G)

001 Body 007 Shaft seal
002 Shaft 008 O-ring ø110.49 x 5.33
003 Spacer bush 011 Lock nut
004 2 Grooved ball bearing 019 Adjusting key
005 2 Circlip ø26 x 1.2 040 Cover
006 2 Circlip ø10 x 1
B 4 Position microswitches SG 16 1 Position transmitter SG 16
Fig. 4-04: Position Transmitter R - SG 16 + 4K(G)
Register 4
POSITION TRANSMITTER R - 4K(G) (SG 16)

001 Body 006 2 Circlip ø10 x 1
002 Shaft 007 Shaft seal
003 Spacer bush 008 O-ring ø110.49 x 5.33
004 2 Grooved ball bearing 019 Adjusting key
005 2 Circlip ø26 x 1.2 040 Cover
B 4 Position microswitches
Fig. 4-05: Position Transmitter R - 4K(G) (SG 16)
Register 4
FIG. 4-01: SINGLE ACTION CONTROL UNIT (SACU) 2

FIG. 4-02: CONTROL UNIT PV 6K 3
FIG. 4-03: CONTROL UNIT PV 8 4
FIG. 4-04: POSITION TRANSMITTER R - SG 16 + 4K(G) 5
FIG. 4-05: POSITION TRANSMITTER R - 4K(G) (SG 16) 6
Register 4
REGISTER 5:
GENERAL MAINTENANCE INSTRUCTIONS
Contents
RECOMMENDATIONS ON REVISION INTERVALS FOR CCI AG / SULZER CONTROL VALVES 3

1 CONTROL VALVES IN GENERAL 3
2 CONTROL VALVES WITH INTEGRATED INJECTION SYSTEM IN THE HP AND LP-BYPASS
SYSTEM 3
3 REPLACING WELDED-IN VALVE SEATS 4
CLEANING INSTRUCTIONS 5
1 REQUIRED CLEANING MATERIALS 5
2 CLEANING METHODS 5
INSTRUCTIONS FOR BOLT THREAD LUBRICATION AND TORQUE SETTINGS

CCI AG / SULZER VALVES (EXCLUDING ACTUATORS) 6
1 LUBRICANT 6
2 LUBRICATING THREADS 6
3 LOOSENING/TIGHTENING SCREWS (BOLTS AND NUTS) WITH TORQUE WRENCHES, TORQUE
AMPLIFIERS OR SINGLE-HEAD HYDRAULIC TORQUE DEVICES 7
4 HYDRAULIC BOLT – PRE-STRESSING – DEVICE WITH CYLINDER PISTON HEADER 8
HYDRAULIC ACTUATOR GHZ(F) 10

1 INSTALLATION 10
2 REMOVING THE COMPLETE ACTUATOR UNIT 11
3 ASSEMBLY OF THE COMPLETE ACTUATOR UNIT 11
HYDRAULIC ACTUATOR GHZ WITH PRESSURE SPRING 13

2 REMOVING THE COMPLETE ACTUATOR UNIT 14
3 ASSEMBLY OF THE COMPLETE ACTUATOR UNIT 16

1 REPLACING THE COMPLETE SINGLE ACTION CONTROL UNIT (SACU) 19
2 REPLACING INDIVIDUAL COMPONENTS 20
CONTROL UNIT PV 6K 22

1 REPLACING THE COMPLETE PV CONTROL UNIT 22
CONTROL UNIT PV 8 24

1 REPLACING THE COMPLETE PV CONTROL UNIT 24
STAND-BY ACCUMULATOR ZS AND ACCUMULATOR MANIFOLD SB 26

1 WORK ON ZS STAND-BY ACCUMULATOR 26
2 WORK ON THE SB ACCUMULATOR MANIFOLD 30
Register 5
General Maintenance Instructions Page 1 of 37
ADJUSTMENT OF POSITION TRANSMITTER SG 16, POSITION MICROSWITCHES AND
POTENTIOMETER 31
1 GENERAL INFORMATION 31
2 ADJUSTMENT 32
INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER 34

1 FITTING 34
2 REMOVING 34
WIRING DIAGRAM OF THE POSITION MICROSWITCHES INSIDE POSITION TRANSMITTERS 35
SERVICE RECORDS 36
Register 5
RECOMMENDATIONS ON REVISION INTERVALS FOR CCI AG / SULZER
CONTROL VALVES
1 Control Valves in General

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

performed by well trained personnel.
2 Control Valves with Integrated Injection System in the HP and LP-Bypass

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

- For plants with the operating, on base load or in a weekend-shut-down mode, are intervals
of maximum 2 years.
- For plants with frequent bypass operation (e.g. daily start-up), at least one valve should be
opened and inspected once a year.
- Depending on the condition of the inspected valve, it will be decided whether or not to
inspect other.
Register 5
For valves used as controlled safety valves, the regulations of local authorities governing
periodic inspections must be observed.
3 Replacing Welded-in Valve Seats

If it becomes necessary to replace valve seats, the welding shall be done according to the
corresponding specification. Requests for welding specifications should be addressed to:
CCI AG
Customer Service
Itaslenstrasse 9
CH-8362 Balterswil, Switzerland
Note:
Exchange of the jammed valve seats is given in the "Dismantling and
Assembly Instructions", of the corresponding valve.
Register 5
CLEANING INSTRUCTIONS
1 Required Cleaning Materials

The following materials should be used to comply with CCI recommended cleaning methods.
Materials and methods may be changed to meet local conditions and requirements.
- crocus cloth, 400 grit
- cleaning cloths
- brush, S.S. wire
- brush, non-metallic
- solvent
- methyl alcohol, anhydrous purified
- ethyl alcohol, anhydrous denatured
- acetone, technical grade
Re-distilled solvents must be equivalent to new solvent.
Solvents may be toxic and flammable. Refer to the manufacturer's

instructions before using. Eye protection is required when solvents or
compressed air is used.
2 Cleaning Methods
The following procedures should be used for cleaning CCI control valve and CCI pneumatic
actuator components.
Do not use abrasives to clean valve components.
1. Immerse parts in solvent.

2. Remove stubborn accumulations of dirt from the sealing surfaces with a non-metallic
brush.
3. Remove scale, rust, and minor pitting from the interior of the body using 400 grit crocus
cloth or a S.S. wire brush.
4. Rinse parts with clean solvent.
5. Direct compressed air through each disk passage, in the reverse direction of flow.
6. Dry parts with cleaning cloths and/or compressed air
Register 5
INSTRUCTIONS FOR BOLT THREAD LUBRICATION AND TORQUE SETTINGS
CCI AG / SULZER VALVES (EXCLUDING ACTUATORS)
Inspections to be carried out before starting work:

- The valve must be depressurized, drained and allowed to cool to ambient temperature.
To ensure quick and easy dismantling during overhauls, all bolts, nuts and screws should be
handled with care and greased in accordance with the instructions below.
1 Lubricant
- Only BLASOLUBE 315 is to be used on all bolted connections on water and steam valves.
CCI AG rejects any responsibility if other lubricants are used.
2 Lubricating Threads
- Inspect bolt and hole threads for impurities and damage, if necessary, re-cut the thread
holes.
Never trim the bolts threads!
1. Lubricate the threads of all the parts of the bolt connections.

2. Fasten the pressure seal plug, the bonnet or the cover, etc. provisionally with 2 or 4 bolts.
3. Screw the rest of the bolts by hand in without washers until the bolt heads are well seated.
4. If a bolt cannot be fully screwed in without exerting force, the threaded hole should be
cleaned and the thread inspected again.
5. Inspect the bolt thread too, and if damaged, use a new bolt.
6. Do not trim the bolt thread!
7. Unscrew and remove all the bolts again.
8. Lubricate the bolt threads thoroughly once again.
9. Apply lubricant to both sides of the washers.
10. Take the washers to the bolts and screws them in.
Bolted connections consisting of threaded bolts and the nuts must also to be treated as
described above.
Register 5
3 Loosening/Tightening Screws (Bolts and Nuts) with Torque Wrenches, Torque
Amplifiers or Single-head Hydraulic Torque Devices
The tightening torques in Nm is given in the valve parts list or top assembly drawing.
If a torque amplifier is used, care should be taken that the stop of the reaction bar for
compensating the reaction forces (torque) is placed as far away from the bolt as possible.
Tighten and loosen the screws (bolts and nuts) ever alternating diagonally in accordance to the
table "Example of bolt tightening sequence".
Hydraulic Torque Wrench
Before start any work, read they the settled operating instruction of the supplier attentively.
Especially the ones concerning accident prevention must be strictly fulfilled.
Determine the hydraulic-pressure according the "Pressure- / torque – table from the
manufacturer
3.1. Loosening the Screws (Bolts and Nuts)

The bolted connections are to be loosened in the following stages:
1. Loosen all screws (bolts or nuts) alternating diagonally (see table "Example of bolt
tightening sequence"), to 50% of the specified torque.
2. Loosen and remove all screws (bolts or nuts) them alternating diagonally completely.
3.2. Tightening the Screws (Bolts and Nuts)

The bolted connections are to be tightened in the following stages:
1. Lubricating and installing of the bolt connection is described under paragraph 1.
2. Tighten all the bolts (or nuts) by hand, alternating diagonally (see table "Example of bolt
tightening sequence").
3. Tighten all screws (or nuts), alternating diagonally to 25% of the specified torque.
Build up the oil pressure required for "25% of specified torque" (see mounting instructions)
counter checks the selected pressure at the pressure gauge.
4. Tighten all bolts (or nuts), alternating diagonally, to 50 % of the specified torque.
5. Tighten all bolts (or nuts), alternating diagonally, to 75% of specified torque.
6. Tighten all bolts (or nuts) to the full specified torque. Build up the oil pressure required for
"full specified torque" (see mounting instructions) counter checks the selected pressure at
the pressure gauge.
7. Repeat the complete cycle as necessary until all screws (or nuts) are tightened equally.
Register 5
Fig. 5-01: Example of Bolt-tightening Sequence
- Tighten bolts in a diagonal sequence.
- Tighten bolts crosswise.
4 Hydraulic Bolt – Pre-stressing – Device with Cylinder Piston Header

- Before starting any work, read the settled operating instruction of the supplier attentively.
Especially the ones concerning accident prevention must be strictly fulfilled.
- A hydraulic bolt – pre-stressing – device consists of a hand lever pump or a pump unit,
4-cylinder piston header and a complete set of hydraulic hoses.
- Pre-stressing force FSO in KN.
- Determine the hydraulic-pressure according the "Pressure- / pre-stressing force FSO in
accordance with the pre-stressing diagram from manufacturer.
Register 5
4.1. Loosening Screws (or Nuts)
1. Mount the 4 cylinder piston header evenly distributed around the circumference, onto the
screws (or nuts), see table "Example of bolt tightening sequence".
2. Loosen the 4 screws (or nuts) to 50% of the specified pre-stressing force.
3. Remove the cylinder piston header from the screws (or nuts) and mount the hydraulic bolt –
pre-stressing – device onto the next 4 screws (or nuts).
4. Loosen and remove all screws (or nuts).
5. Dismantle the hydraulic bolt – pre-stressing – device.
4.2. Tightening Screws (or Nuts)

1. Lubricating and installing of the bolt connection is described under paragraph 1.
2. Mount the 4 cylinder piston header on the screws (or nuts) evenly distributed around the
circumference, onto the screws (or nuts), see table "Example of bolt tightening sequence".
For safety reasons, the studs must protrude over the nuts by at least 2
threads!
3. The necked-down bolts will be tensed with 50% of the force in accordance with in the
diagram identified force FSO and the nuts until it sits solidly.
4. The necked-down bolts are again with 50% of FSO force retightened until the nuts can`t be
turned anymore!
5. Check the clearance "S", whether the cover is parallel and in seat solidly.
6. The necked-down bolts will be tensed with 100% of the force FSO and the nuts has to be
brought in a solid seat position.
7. Necked-down bolts once more with 100% of the force FSO tightened until the nuts can't be
turned anymore!
Register 5
HYDRAULIC ACTUATOR GHZ(F)
1 Installation
The description of the maintenance work is accompanied by illustrations of a general nature,
which show the sequence of work as clearly as possible. Since GHZ actuators come in various
sizes and design, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to any particular actuator.
Work on actuators should only be done by trained personnel!
GHZ Actuator SE Control unit

KS Piston rode R-SG Feedback unit
Fig. 5-02: Actuator GHZ, Installation
Always secure the actuator unit with a lifting gear!

Pay attention to the actuator unit to prevent from slipping out!
Take care not to scratch the valve stem with the yoke!
Register 5
2 Removing the Complete Actuator Unit
1. Run the actuator unit to the mid-position of its stroke.
2. Close the valve in the hydraulic line and drain existing accumulators.
3. Disconnect all connectors.
4. Disconnect all hydraulic hoses and plug all openings.
5. Remove safety wire on articulated joint 013 and disconnect the joint.
6. Unscrew and remove guide arm 009, unions 010,011 and coupling 008.
7. Make a note of the distance "a" between the actuator spindle and the valve stem.
8. Mark the position of actuator unit relative to valve.
9. Secure the actuator unit with a lifting gear, loosen and remove bolts between actuator unit
and valve 006 and 007.
10. Remove actuator.
3 Assembly of the Complete Actuator Unit

1. Attach the complete actuator unit to lifting gear and position it on the valve, observing the
marking.
2. Bolt the yoke to the valve, using the required torque.
3. Connect the hydraulic hoses to the actuator.
4. Fill the actuator with hydraulic fluid and de-aerate it.
5. If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
actuator gets isolated from the hydraulic supply system and the remains pressurized.
In order to avoid excessive pressure increase inside the hydraulic actuator
by temperature increase of the oil in the actuator e.g. through solar
radiation or radiation from other plant components, the oil pressure of the
actuators must be released through the Minimess connections.
6. Re-connect and secure articulated joint 013.
7. Check valve stroke and adjustment of position transmitter.
8. Re-make all electrical connections.
9. Manually operating the control unit and drive the actuator down onto the valve stem and
force the valve stem into the seat.
10. Drive the actuator the same distance "a" in the "Valve open" direction, as was measured
between the actuator spindle and valve stem under Par. 1.7.
11. When fitting the coupling, be sure to use only coupling halves with identical markings. Be
sure that the valve stem threads exactly match those of the coupling. Tighten the coupling
bolts.
Never operate actuator before tightening the coupling bolts.

Otherwise the threads of valve stem and coupling may become damaged.
Register 5
12. Drive the actuator travel in the "Valve open" direction until it rests against the stop. Check
that the required stroke is indicated on the scale. If not, adjust the scale.
13. Drive the actuator in the "Valve closed" direction until it rests against the stop. Check that
the indicator is in line with the zero mark on the scale.
14. If it is not, drive the actuator into its mid-position, loosen the coupling bolts and
compensate the difference by rotating the valve stem. Re-tighten the coupling bolts.
Never rotate the valve stem while it rests on the valve seat, otherwise the
stem seating surfaces will be damaged.
15. Drive the actuator into its end positions "Valve open" and "Valve closed" again and check
the valve stroke against the scale readings.
16. If necessary, rotate the valve stem again as described above.
17. Tighten the coupling bolts. For the bolt tightening torques to be applied, see corresponding
Parts list in register "Sectional Drawings & Parts List".
Register 5
HYDRAULIC ACTUATOR GHZ WITH PRESSURE SPRING
The description of the maintenance works is accompanied by generally accepted, three-
dimensional illustrations showing the work procedure ideally. As the actuators GHZ are built
in different sizes and shapes, the figures and details of the individual parts do not correspond to
the reality in every case.
More detailed information about the individual items can be found in the drawing "valve with
actuator" and the related stock parts list.
Any work on the actuator is only to be performed by well trained

personnel.
Item Part Name Item Part Name

GHZ Actuator DF Pressure spring
SE Controller (SACU) ZS Intermediate rod
KS Piston rod K Coupling
KR Tensioning ring R-SG Displacement transducer
Fig. 5-03: Actuator GHZ with Spring
Register 5
2 Removing the Complete Actuator Unit
2.1. Removal of the Complete Actuator Unit from the Valve Body
Fig. 5-04: Disassembly / Assembly of Actuator Unit / Valve

1. Move the actuator into the middle stroke position.
2. Close the cock of the hydraulic line (P), empty existing storages.
3. Remove all plugs.
4. Remove hoses and close openings.
5. Remove safety wire to angle joint 013 and unhinge angle joint.
6. Remove adjustment retainer 009, incl. screwed connection 010, 011, as well as coupling
008.
7. Measure and document distance "a" between piston rod and valve spindle.
8. Mark position lantern - valve.
9. Attach actuator to a crane, loosen and remove screwed connection lantern / valve 006 / 007.
10. Remove the actuator.
Register 5
2.2. Disassembly of the Actuator from the Spring Pack
Fig. 5-05: Disassembly / Assembly of Spring Pack

1. Screw the bolts 020 into the lower spring plate 004 and tighten equally until the distance
(X) between spring plate 003 and 004 is at least 70mm.
2. Pull intermediate rod 005 downwards, so that both coupling ring halves 009 are free.
3. Remove coupling ring halves 009.
4. Loosen and remove screwed connection actuator – spring 016/017.
5. Attach actuator to a crane and pull it carefully upwards together with the intermediate rod
005.
2.3. Disassembly of the Intermediate Rod

1. Remove tensioning ring 019.
2. Unscrew intermediate rod 005 from the piston rod.
Register 5
2.4. Disassembly of the Spring Pack from the Lantern
1. Relieve pressure of the spring by equally unscrewing the four bolts 020 from the lower
spring plate 004.
2. Loosen and remove the bolts 011 together with the spring washers 012.
3. Remove the 4 tie anchors 007 and separate the spring 006 and the 3 spring flanges.
4. If necessary, loosen bolts 013 and disassemble them together with the spring washers and
the guide sleeve 008.
5. Clean all parts and check for damages.
3 Assembly of the Complete Actuator Unit
3.1. Assembly of the Spring Pack

1. If necessary, replace guide rings 010.
2. If the guide sleeve 008 has been disassembled, it has to be reassembled with the specified
torque using the bolts 014.
3. Assembly of the 4 tie anchors 007 in the lower spring flange 004 using the screwed
connection 011/012 with the specified torque, taking the 4 self-locking pins 015.
4. Assembly of the spring flanges, the spring and the tie anchors.
5. Assembly of the 4 tie anchors 007 in the upper spring flange 002 using the screwed
connection 011/012 with specified torque.
3.2. Assembly of the Spring Pack to the Lantern

- Assemble screwed connection spring flange 004 – lantern with the specified torque.
3.3. Assembly of the Intermediate and the Piston Rods to the Hydraulic Actuator
1. Screw intermediate rod 005 onto the piston rod (screw-in depth = 35mm).
2. Secure the connection by mounting the tensioning ring 019.
The slots of the intermediate rod and of the tensioning ring have to point in
the same direction.
Register 5
3.4. Assembly of Hydraulic Actuator to Spring Pack
1. Screw the 4 bolts 020 equally into the lower spring flange 004, until the distance between
spring flange 003 and 004 is large enough to be able to install the two coupling ring halves
( x = min 70mm ).
2. Mount the hydraulic actuator carefully on the spring flange 002 using hoist gear and crane.
Lower the actuator slowly.
Pay attention not to damage the intermediate rod 005 and the guide sleeve
008.
3. Mount the screwed connection cylinder – spring flange 002 with the bolts 016 and the
spring washers 017 and tighten to the correct torque.
4. Extend actuator (piston rod) completely and then push the coupling ring halves 009 onto
the intermediate rod 005 on both sides.
5. Push piston and intermediate rod upwards, until they make contact with the spring plate
003.
6. Equally unscrew and remove the assembly screws 020.
3.5. Installation of the Complete Actuator

1. Connect actuator to a crane and lower it over the valve. Observe marking
2. Bolt the yoke to the valve, using the required torque
3. Connect the hydraulic hoses to the actuator.
4. Fill the actuator with hydraulic fluid and de-aerate it
5. If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
If the hydraulic systems are shut down during shorter standstills of the
boiler, i.e. depressurized, the blocking elements enclose the system oil
pressure in the actuators.
In order to prevent an unallowable increase of the oil pressure due to

additional heating, e.g. due to boiler and/or direct solar radiation or due to
an un-insulated valve, the oil pressure of the actuators has to be released
using the MINIMESS- ports.
6. Re-connect and secure articulated joint 013
7. Check valve stroke and adjustment of position transmitter
8. Re-make all electrical connections
9. Manually operating the control unit and drive the actuator down onto the valve stem and
force the valve stem into the seat.
10. Drive the actuator the same distance "a" in the "Valve open" direction, as was measured
between the actuator spindle and valve stem under Par. 1.1.7.
11. When fitting the coupling, be sure to use only coupling halves with identical markings. Be
sure that the valve stem threads exactly match those of the coupling. Tighten the coupling
bolts.
Register 5
Never operate actuator before tightening the coupling bolts. Otherwise the
threads of valve stem and coupling may become damaged.
12. Drive the actuator travel in the "Valve open" direction until it rests against the stop. Check
that the required stroke is indicated on the scale. If not, adjust the scale.
13. Drive the actuator in the "Valve closed" direction until it rests against the stop. Check that
the indicator is in line with the zero mark on the scale.
14. If it is not, drive the actuator into its mid-position, loosen the coupling bolts and
compensate the difference by rotating the valve stem. Re-tighten the coupling bolts.
Never rotate the valve stem while it rests on the valve seat. Otherwise the
stem seating surfaces will be damaged.
15. Drive the actuator into its end positions "Valve open" and "Valve closed" again and check
the valve stroke against the scale readings.
16. If necessary, rotate the valve stem again as described above.
17. Tighten the coupling bolts. For the bolt tightening torques to be applied, see corresponding
Parts list in register "Sectional Drawings & Parts list".
Register 5
Work must only be carried out on the single action control unit (SACU) if the installation is
shut down or if the relevant valve can be isolated. Even under these conditions, we recommend
that the complete control unit should be replaced and that any other work should be carried out
in the comfort of a clean workshop.
This work is only to be carried out by trained personnel.

All bolts and nuts must be tightened to the specified torques.
1 Replacing the Complete Single Action Control Unit (SACU)
1.1. Removal
1. Run the actuator to its lowest position to ensure that hydraulic fluid does not escape from
the actuator after removal of the control unit.
2. Unscrew the electrical connectors (004).
3. Close the shut-off valves in pressure line (P).
4. Release hydraulic pressure using the venting screw on the actuator.
5. Unscrew hydraulic hoses.
6. Unscrew and remove hexagon socket screws SW6 M8 (014) and lift off the stepping
control unit.
7. Clean all hydraulic bores seals.
1.2. Installation
1. Smear two new O-rings (016) with hydraulic fluid and place them in the grooves on the
back of the control unit.
2. Fit the stepping control unit with 4 Hexagon socket screws SW6 M8 (014) and washers.
3. Connect hydraulic lines and electrical connectors.
4. Slowly open the shut-off valves in the pressure line (P).
Register 5
001 Manifold 012 Check-valve
002 2 EO Screw plugs M18 x 1.5-ED 013 3 3/2-Way seat-valve NG4/G24
003 5 Expander KOENIG 014 4 Screw M8 x 100; SW6; Ma=23Nm
004 3 Electrical connectors 015 4 Spring washer ø 8.4 x 14
009 2 EO Screw XGE 25-SM-ED 016 2 O-Ring ø 25.07 x 2.62
010 2/2-Way valve NG16 020 2 EO Screw plugs XRED 25/20-S
011 Cover
Fig. 5-06: Replacing the Complete Single Action Control Unit (SACU)
2 Replacing Individual Components

- Replace the EO Screw plugs (002, 007, 019, 020), the Integration check valves (005, 006),
the 2/2-Way valve NG16 (011, 010), the Check-valve (012) and the 3/2-Way seat-valve
NG4/G24 (013) in accordance with the exploded assembly drawing: "Replacing the
individual components".
Register 5
001 Manifold 98 x 99 x 255 012 Check-valve
002 2 EO Screw plugs M18 x 1.5-ED 012.10 O-Ring ø29.82 x 2.62
003 5 Expander KOENIG 012.20 O-Ring ø 25. x 1.78
004 Name plate 012.30 O-Ring ø 23.52 x 1.78
005 Integration check valve 012.40 Backup-ring ø 26.1 x 29 x 1.4
006 Integration check valve 012.50 Backup-ring ø 26.1 x 29 x 1.4
007 EO Screw plugs R3/4-ED 013 3 3/2-Way seat-valve NG4/G24
Screws M5 x 45; SW4; Ma=5.5
009 2 EO Screw XGE 25-SM-ED 013.01 12
Nm
010 2/2-Way valve NG16 013.02 12 Washers ø9.2 / 5.3
010.10 O-Ring ø26.64 x 2.62 013.70 9 O-Ring ø5.28 x 1.78
010.40 Cover – Seal ø 32/27.5x5.1 016 2 O-Ring ø 25.07 x 2.62
010.50 Cover – Seal ø 25/20.5x5.2 019 EO Screw plugs R3/8-ED
011 Cover 020 2 EO Screw plugs XRED 25/20-S
Screws M8 x 50 SW6;
011.01 4
Ma=23Nm
Fig. 5-07: Replacing the Individual Components
Register 5
CONTROL UNIT PV 6K
Work must only be carried out on the PV control unit if the installation is shut down or if the
relevant valve can be isolated. Even under these conditions, we recommend that the complete
control unit should be replaced and that any other work should be carried out in the comfort of
a clean workshop.

1 Replacing the Complete PV Control Unit
1.1. Removal
2. Unscrew the electrical connectors.
3. Close the shut-off valves in pressure line.
6. Unscrew and remove hexagon socket screws and lift off the PV-control unit.
1.2. Installation
1. Smear two new O-rings with hydraulic fluid and place them in the grooves on the back of
the PV control unit.
2. Fit the PV control unit with 4 Hexagon socket screws and washers.
4. Slowly open the shut-off valves in the pressure line.
If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
Register 5
PV4_PV6k_E05-Figure.tif

Screws M5 x 45 SW4,
10 1 Distributor plate NG6 60 3
Ma = 5.5 Nm
Screw coupling to mini-measuring Screws M5 x 50 SW4,
20 2 70 4
device 1620 / M14 x 1.5 ED Ma = 5.5 Nm
Screws M6 x 60 SW5,
30 2 Check valve 90 4
Ma = 9.5 Nm
40 1 3/2-way solenoid valve 110 2 O-ring Ø 25.07 x 2.62, Viton
50 1 Proportional solenoid valve NG6 130 2 Connections for P & T
Fig. 5-08: Replacing Individual Components of the PV 6k
All replaced valves are maintenance-free.
Faulty valves need to be replaced by new valves.
Register 5
CONTROL UNIT PV 8
Work must only be carried out on the PV control unit if the installation is shut down or if the
relevant valve can be isolated. Even under these conditions, we recommend that the complete
control unit should be replaced and that any other work should be carried out in the comfort of
a clean workshop.

1 Replacing the Complete PV Control Unit
1.1. Removal
2. Unscrew the electrical connectors.
3. Close the shut-off valves in pressure line.
6. Unscrew and remove hexagon socket screws and lift off the PV-control unit.
1.2. Installation
1. Smear two new O-rings with hydraulic fluid and place them in the grooves on the back of
the PV control unit.
2. Fit the PV control unit with 4 Hexagon socket screws and washers.
4. Slowly open the shut-off valves in the pressure line.
If the hydraulic supply unit is switched off and the hydraulic system gets depressurized, the
Register 5
PV6_PV8_E05-Figure.tif
Drawings: 103.227.861.500 / 103.227.862.500

Screws M 5 x 45
10 1 Distributor plate NG 8 60 3
SW4, Ma = 5.5 Nm
Screw coupling to Mini-measuring Screws M 6 x 65
20 2 70 4
system 1620/ M 14 x 1.5 ED SW5, Ma = 9.5 Nm
Check valves SUN Cvev xev, Screws M 8 x 80
30 2 90 4
Wandfluh SW6, Ma = 23Nm
3/2-way poppet valve BM32041a,
40 1 110 2 O-Rings Ø 25.07 x 2.62, Viton
Wandfluh
Proportional directional control
Screw connector GE20-SM-ED-
50 1 valve, NG 10 APWS4D101, 130 2
Viton
Wandfluh
Fig. 5-09: Replacing Individual Components of the PV 8
All replaced valves are maintenance-free.
Faulty valves need to be replaced by new valves.
Register 5
STAND-BY ACCUMULATOR ZS AND ACCUMULATOR MANIFOLD SB
The stand-by accumulator is delivered for safety reasons for transport

without nitrogen charging pressure.
Before commissioning all accumulators in the system have to be filled up with
nitrogen to the appropriate charging pressure.
The nominal value of the charging pressure is specified in the hydraulic data
sheet in the corresponding register.
Work may only be carried out on the SSB safety control units when the system is shut down.
We recommended working in a clean workshop if possible.

Threaded connections must be tightened to the specified torque.
1 Work on ZS Stand-by Accumulator
1.1. Checking the Gas Charge Pressure

The gas charge pressure must be checked during the normal overhaul operations. This can be
done in two ways:
- by using the pressure gauge on the accumulator manifold, or
- with the pressure gauge on the nitrogen filling unit.
The procedure for the second method is described in Section 1.2.
The operations described below refer only to measurement with the built-in pressure gauge:
- Close the valve in pressure line (P) upstream of the stand-by accumulator.
- To minimize the N2 temperature loss, slowly reduce the pressure using the pressure relief
valve (022) on the accumulator manifold.
- Observe the pressure gauge: once the pressure has dropped to the N2 charging pressure (oil
fully discharged), the pressure gauge reading immediately drops to zero. The reading before
dropping is the N2 pressure.
- Set the pressure relief valve again by turning clockwise to the stop.
- Slowly open the valve in the supply line of the accumulator, the gauge reading jumps to the
N2 charging pressure
If the N2 charging pressure is below the pressure given in the Data sheet, nitrogen must be
added (see 1.2).
Register 5
017 1 Pressure gauge 022 1 Pressure relief valve
Fig. 5-10: Checking the Gas Charge Pressure
1.2. Topping-up with Nitrogen

For topping up nitrogen in the gas bladder, we recommend using the special filling equipment
for OLAER accumulators.
1. Unscrew the sealing cap (042) of the stand-by accumulator and take off the valve cap.
2. Check the gas-tightness of the gas valve insert (044) with leak tracing spray or soap
solution. If the gas valve insert is leaking, the gas must be vented off and the insert
replaced.
Do not use a car tire valve!
3. Screw the filling unit on to the accumulator.

4. Connect the filling unit hose to the nitrogen bottle.
5. Close the filling unit venting valve.
6. Open the valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.
7. Measure the gas charge pressure: close the valve on the nitrogen bottle, screw in the
knurled screw and note the charge pressure on the filling unit pressure gauge.
8. Reduce the gas charge pressure if it is too high: with the gas bottle valve closed, open the
venting valve, screw in the knurled screw and slowly open the venting valve
The charge pressure depends on the temperature. Since the filling process
affects the temperature, it is advisable to wait five minutes after the
nominal charge pressure has been reached to allow the gas temperature to
stabilize. Measure the pressure again and correct it if necessary.
Register 5
9. Close the valve on the nitrogen bottle.
10. Open the venting valve on the filling unit.
11. Remove the filling unit.
12. Fit the valve cap (043).
13. Screw on the sealing cap (042) and tighten.
14. Check gas tightness with leak tracing spray or soap solution. Repair leaks immediately,
since they inevitably result in the destruction of the gas bladder in the accumulator.

024 1 Accumulator 043 1 Valve cap
042 1 Sealing cap 044 1 Gas valve insert
F 1 Filling unit
Fig. 5-11: Filling Connector on Stand-by Accumulator
1.3. Replacing the Complete Stand-by Accumulator

1.3.1. Removal
1. Close the valve in pressure line (P) upstream of the accumulator.
2. Release the pressure in the accumulator by opening the pressure relief valve (022).
3. Disconnect all hydraulic connections to the SB accumulator manifold.
4. Unscrew the accumulator manifold from the accumulator.
5. Slacken the accumulator holder clamps (040) and using lifting gear, lift the accumulator out
vertically upwards.
Register 5
1.3.2. Installation
1. By using a lifting gear, lower the replacement accumulator vertically downwards into the
accumulator holder.
2. Fit the O-ring (2.1) onto the adapter nipple of the accumulator manifold.
3. Screw the accumulator manifold on to the accumulator from below.
Do not over tightening the screws!
4. Turn the accumulator until the accumulator manifold is correctly positioned relative to the
hydraulic connections.
5. Tighten the clamps (040) and connect all hydraulic lines.
6. Check the nitrogen filling pressure while accumulator is empty. If necessary, fill with
nitrogen until the filling pressure has reached the value indicated on the hydraulic data
sheet.
7. Slowly open the valve in pressure line (P) and check the connections for leaks.

022 1 Pressure relief valve 040 1 Clamps
2.1 1 O-ring (see drawing 01-EL00001-3, OLAER)
Fig. 5-12: Replacing the Accumulator
Register 5
2 Work on the SB Accumulator Manifold
2.1. Setting the Pressure Switch (Option)

The pressure switch gives an electrical signal as soon as the pressure in the accumulator drops
below the minimum setting. The pressure measurement necessary for setting the pressure
switch is done with the pressure gauge on the accumulator manifold. The pressure switch is
not standard equipment.
2.2. Measuring of Pressure Switch Operating Pressure

The operating pressure must always be measured with falling pressure. Therefore, the
accumulator must be fully filled at the beginning of the check.
1. Close the valve in the pressure line (P) upstream of the accumulator.
2. Slowly reduce the pressure using the pressure relief valve (022).
3. Note the pressure at which the pressure switch operates. Operation of the pressure switch
can be observed on a suitable gauge connected directly to the pressure switch.
4. Slowly open the valve in the pressure line (P).
Register 5
ADJUSTMENT OF POSITION TRANSMITTER SG 16, POSITION MICROSWITCHES
AND POTENTIOMETER
1 General Information
1.1. Types
Tab. 5-01: Types of Abbreviations SG 16
R - SG 16 Position transmitter
R - 4K Limit switches
R - SG 16 + 4K Position transmitter with position microswitches
Position transmitter with position microswitches and position
R - SG 16 + 4K + P
potentiometer
The letter R-... signifies that the units are installed in the housing. Gas-proof position
microswitches are marked with the letters KG.
1.2. Technical Specifications

Position transmitter SG 16
(see also register 3: "Description of Main Components", paragraph 9.)
Tab. 5-02: Position Microswitches SG 16
Type K (standard) Type KG (gas-proof)

Contact ratings resistive inductive resistive inductive
Nominal voltage 220 V ~ 10 A 10 A 2.5 A 1.5 A
125 V ~ 10 A 10 A
115 V = 0.5A 0.03A 1A 0.5 A
50 V = 1A 1A
30 V = 5A 3A
Tab. 5-03: Position Potentiometer SG 16
SG 16
Max. Ohmic resistance 1300 Ω @ 90°
Contact rating (at 40°C) 1W
Max. current for slider 120 mA
Max. angle of rotation 360°
Register 5
1.3. Electrical Connections
Position transmitter (+/-) by use of ferrule crimps
Potentiometer (18-20) with AMP Fast-On 6.3
Position microswitches on terminal blocks 0.5... 2.5 mm2 (6-17) by use of ferrule crimps
2 Adjustment
The exact position of the articulated joint on the position transmitter lever is set in the works.
- The distance between articulated joint and position transmitter axis must be equal to the
valve stroke (see valve data sheet).
- At 50 % valve stroke, the lever should be almost horizontal. If not, correct the adjustment
using the connecting bolt between the articulated joints.
To adjust the position transmitter, the position microswitches and the potentiometer, loosen the
two screws and remove the cover. The actuator must be free to operate over its entire stroke
(see valve data sheet). The position transmitter module in the control cubicle must be operable.
2.1. Position Transmitter

- Ensure that the transmitter is correctly mounted, correctly coupled with the housing shaft
(locknut SW17mm) and the electrical connections completed (supply voltage 24VDC and
correct polarity):
+24V on terminal 1
Signal 4…20mA on terminal 2
- Depending on the sense of rotation the link 3 / 4 has to remain for counter clockwise
operation or has to be removed for clockwise operation.
Disconnect power supply to transmitter before inserting or removing the
link.
- Connect an ammeter with a range of at least 0 to 20 mA, in series with the position
transmitter. For this purpose the + line is to be disconnected and connected to the
instrument. The second instrument connection is to be attached to the open terminal on the
position transmitter.
- Setting of the initial position (0 % = 4 mA):
Move valve to "Closed" position. Push button "0 %" for a time of 0.5 .. 1 s
- Setting of the final position (100 % = 20 mA):
Move valve to "Opened" position. Push button "100 %" for a time of 0.5 .. 1 s
Important Information:
- Programming order (0 % ; 100 %) has to be kept.
- In case of pushing a button too long or too short (>1s or<0.5s) during a setting operation the
setting is not stored.
- Disconnect the ammeter and reconnect the position transmitter.
Register 5
2.2. Position Microswitches
Each limit switch is set individually, the procedure being the same for each.
1. Run the actuator in the direction in which it operates the switch, until the intended
switching position has been reached. While doing so observe the rotational direction of the
shaft.
2. Rotate the corresponding cam in the same direction until the required switching action
takes place.
Depending on which half of the cam profile is used, pressing or releasing of
the switch lever results. The cam is rotated with the adjusting lever located
on the frame. It is sufficient that only one pin engages with one of the cam
plate holes and that the other is in contact with cam plate profile. It is not
necessary to lock the cam plates; they are kept in position by disc springs.
2.3. Position Potentiometer

The potentiometer is coupled to the position transmitter drive shaft.
1. Run the actuator to the end position at which the slidewire connection of the potentiometer
gives 0 Ohm.
2. Run the actuator until it just moves away from its end position and observe the rotational
direction of the drive shaft. Run the actuator back to its starting position.
3. Insert a screwdriver into the free shaft end and rotate the potentiometer in the opposite
direction until the stop is felt.
The resistance between one end of the potentiometer winding and the
slidewire connection increases when the actuator is operated toward the
other end position. The maximum resistance value reached is dependent on
the angle of rotation. The polarity of the end connections, 18 and 20, must
be checked.
Register 5
INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER
The position transmitter 2,0 is fitted with a damping element 1,1 to minimize vibration from
the actuator yoke.
1 Fitting
1. Loosen screw 4,2 and remove lever 4,1 from the dummy shaft.
2. Remove the dummy.
3. Fit position transmitter to the yoke, using screws 1.6 and washers 1,5.
4. Slide lever 4,1 onto the shaft of position transmitter and tighten the screw 4,2.
5. Adjust the position transmitter according to Instruction "Setting-up the Feedback unit with
Position Transmitter SG 15 A/B, Position Microswitches and Potentiometer".
2 Removing
1. Loosen screw 4,2 and remove lever.
2. Loosen and remove screws 1,6 and washers 1,5.
3. Replacing the damping element
4. Remove the position transmitter as above described.
5. Loosen the screws 1,4 and remove the damping element 1,1, rubber discs 1,2 and washers
1,3
6. Clean and fit new damping elements, rubber discs, screws and washers if necessary.
Fig. 5-13: Instructions for Fitting and Removing the Position Transmitter
Register 5
WIRING DIAGRAM OF THE POSITION MICROSWITCHES INSIDE
POSITION TRANSMITTERS
Color of wires:
gn = green
rt = red
ws = white
SG = Position Transmitter
Fig. 5-14: Wiring diagram of the Position Microswitches Inside Position Transmitters
Register 5
SERVICE RECORDS
Customer
Plant
Valve identification
Plant valve TAG
CCI-Valve No.
Erection date Date Sig. Notes

Assembly
Commissioning
Schedule 1) Activities Date Sig. Notes

Valve; General inspection:
Check jet cage and valve seat, replace
1st year + sealing rings and packings
---- ---- ----
every 2 years Actuator; General inspection:
Visual check of leakage, check
positioner loop
Actuator:
every 6 years ---- ---- ----
Replace hydraulic hoses
every 10 Actuator:
---- ---- ----
years Replace all sealing rings
Schedule 1) Activities Date Sig. Notes

st
1 General inspection
1) See also: "Recommendations for overhaul intervals for CCI AG / SULZER-control

valves", and also consult the regulations of the responsible local Authorities. For further
information, contact:
Customer Service
CCI AG
Itaslenstrasse 9
CH-8362 Balterswil
Switzerland
Register 5
FIG. 5-01: EXAMPLE OF BOLT-TIGHTENING SEQUENCE 8

FIG. 5-02: ACTUATOR GHZ, INSTALLATION 10
FIG. 5-03: ACTUATOR GHZ WITH SPRING 13
FIG. 5-04: DISASSEMBLY / ASSEMBLY OF ACTUATOR UNIT / VALVE 14
FIG. 5-05: DISASSEMBLY / ASSEMBLY OF SPRING PACK 15
FIG. 5-06: REPLACING THE COMPLETE SINGLE ACTION CONTROL UNIT (SACU) 20
FIG. 5-07: REPLACING THE INDIVIDUAL COMPONENTS 21
FIG. 5-08: REPLACING INDIVIDUAL COMPONENTS OF THE PV 6K 23
FIG. 5-09: REPLACING INDIVIDUAL COMPONENTS OF THE PV 8 25
FIG. 5-10: CHECKING THE GAS CHARGE PRESSURE 27
FIG. 5-11: FILLING CONNECTOR ON STAND-BY ACCUMULATOR 28
FIG. 5-12: REPLACING THE ACCUMULATOR 29
FIG. 5-13: INSTRUCTIONS FOR FITTING AND REMOVING THE POSITION TRANSMITTER 34
FIG. 5-14: WIRING DIAGRAM OF THE POSITION MICROSWITCHES INSIDE POSITION TRANSMITTERS 35
TAB. 5-01: TYPES OF ABBREVIATIONS SG 16 31

TAB. 5-02: POSITION MICROSWITCHES SG 16 31
TAB. 5-03: POSITION POTENTIOMETER SG 16 31
Register 5
REGISTER 6:
DISMANTLING & ASSEMBLY
Contents
Register 6.1:
- Hydraulic Actuators GHZ & GHZ-F
- Installation and Retightening of "GARLOCK 9000 EVSP" Packing
Rings
- Installation and Retightening of "GRAPHITE" Packing Rings
- Fault Finding and Recommended Repair for Valves and Actuators
Register 6.2:
- LP Isolation and Control Valve NA 60-500 / NB 60-500-2 202787-1CH
Register 6.3:
- LP Spray Water Control Valve DRAG® 840H 202787-2CH
Register 6
Dismantling & Assembly Page 1 of 1
REGISTER 6.1:
DISMANTLING & ASSEMBLY OF
HYDRAULIC ACTUATORS
Contents
HYDRAULIC ACTUATORS GHZ & GHZ-F 2

1 GENERAL INSTRUCTIONS 2
2 PISTON ROD GASKETS 4
3 DISMANTLING INTO INDIVIDUAL PARTS 6
4 ASSEMBLY 6
5 FITTING INSTRUCTIONS FOR INDIVIDUAL COMPONENTS INSTALLATION 9
INSTALLATION AND RETIGHTENING OF "GARLOCK 9000 EVSP" PACKING RINGS 10
INSTALLATION AND RETIGHTENING OF "GRAPHITE" PACKING RINGS 13

1 ASSEMBLY OF NEW GRAPHITE PACKING RINGS 13
2 RETIGHTENING OF GRAPHITE PACKING RINGS 15
FAULT FINDING AND RECOMMENDED REPAIR FOR VALVES AND ACTUATORS 16
LIST OF FIGURES REGISTER 6.1 17
LIST OF TABLES REGISTER 6.1 17
Register 6.1
Dismantling & Assembly of Hydraulic Actuators Page 1 of 17
HYDRAULIC ACTUATORS GHZ & GHZ-F
These instructions are intended for the execution of maintenance and cleaning works as well as
for the replacement of packing kits or seal rings.
Binding Descriptions:
"Descriptions of Main Components" in Register 3
"General Maintenance Instructions" in Register 5
Faulty or damaged actuators are to be completely replaced!
1 General Instructions
Checks to be carried out before starting work:
- The valve must be depressurized.
- All electric supply lines must be de-energized.
- The piping system to the hydraulic actuators must be depressurized
- When several valves are dismantled at the same time, care must be taken that the parts from
different valves are not mixed up.
- Before the assembly, all parts are to be cleaned and inspected for possible damages.
- When assembling, use only new gaskets.
- Screw connections must be done as described in the "General maintenance instructions".
The tightening torqueses apply to correctly lubricated bolts and nuts at room temperature.
All repair and maintenance works on actuators must only be carried out by
qualified and trained personnel.
1.1. Figures and Illustrations

The description of the maintenance work is accompanied by illustrations of a generally
applicable nature, which show the sequence of work as clearly as possible. Since valves come
in various sizes, the proportions and details of the individual components as shown in the
illustrations will not always correspond exactly to a particular valve. For further information to
a single position please consider the corresponding drawing and parts list.
1.2. Maintenance
Work that have to be carried out on the actuator is only possible, if the installation is not in
operation at that time or if the corresponding valve can be isolated.
We strongly recommend that no maintenance work should be done on actuators in situ. Large
amounts of hydraulic fluid are almost certain to escape. Wherever possible, actuators should be
removed complete and dismantled in a clean workshop. This has the additional advantage that
the actuator can always be dismantled in the upright position, which makes the work far easier.
Register 6.1
If for some reason the drive that requires maintenance cannot be removed completely, an
attempt can be made - depending on the mounting position of the actuator - to draw off at least
some of the hydraulic fluid with a suitable pump. Large collecting trays will still need to be
provided and the greatest possible care must be taken.
Warning:
When removing the piston rod, remember that the fluid behind the piston
will escape!
GHZ_Explosionsbild-komplett.tif
Fig. 6.1-01: Exploded View GHZ / GHZ-F Actuators
1.2.1. In Site
- Make sure that the medium (e.g. steam) is not exerting any forces on the valve stem.
- If the actuator is equipped with a hydraulic stand-by accumulator:
- Close the valve in the pressure line to the accumulator and drain the accumulator to the tank
via the release valve in the accumulator manifold.
1.2.2. In the Workshop
- Prepare a collecting pan in which the valve actuator unit (actuator plus yoke) can be stood
upright.
- Prepare ether works area so that there are sufficient clean surfaces for all materials.
Extreme cleanliness must be observed when replacing seals!
Register 6.1
2 Piston Rod Gaskets
2.1. Design for "Mineral Oils"
Pos. # Parts Name

003 1 Hydraulic cylinder head
004 1 Threaded bush
020 2 Guide rings
021 2 Piston rod seal, Polypac-Selmaster
022 1 Scraper ring Lubroseal
Fig. 6.1-02: GHZ Piston Rod Gasket, Design for "Mineral Oil"
Register 6.1
2.2. Design for "Phosphate Ester Fluid"
Pos. # Parts Name

003 1 Hydraulic cylinder head
004 1 Threaded bush
017 1 O-ring, Viton
020 2 Guide rings Viton
021 2 Piston rod Turcon Stepseal with O-rings, Viton
022 1 Scraper ring Turcon Excluder with O-ring, Viton
Fig. 6.1-03: GHZ-F Piston Rod Gasket, Design for "Phosphate Ester Fluid"
Register 6.1
3 Dismantling into Individual Parts
1. Disassemble the actuator from the valve and put it into a tray.
2. Dismount the existing control unit from the cylinder plate. The connection openings of the
control unit are to be closed by means of plugs.
3. Loosen the bleeder screw 010 on the cylinder plate.
4. Loosen and remove the screw connections on the hydraulic tube.
Caution: Hydraulic fluid flows out!
5. Loosen the screw connection 012 between the cylinder head and the cylinder tube.
6. The mounting group: carefully draw the complete piston rod and piston, the complete
cylinder head with the short bushing and seals out of the cylinder tube.
7. Dismantle the mounting group into its individual parts. Remove all seals from the short
bushing.
8. Loosen and remove the screw connection 011b between the cylinder plate and the cylinder
tube.
9. Carefully take the cylinder plate out of the cylinder tube. Remove the O-ring 016.
10. Clean all parts thoroughly and check them for damages.
4 Assembly
4.1. Piston
- The piston is screwed to a piston rod, locked with set screw and secured with Loctite, so
that they build a single mounting group.
In case of damage, wear, and tear, the mounting group must be replaced
entirely!
4.2. Replacement of Piston Seal Kit 019

Provide a new piston seal kit.
- Dismantle the piston seal kit in its individual parts. Moisten all parts with hydraulic fluid
and fit them on the piston by means of an appropriate device.
- A suggestion for a mounting device, see section 5, "Fitting instructions for individual
components installation".
Register 6.1
4.3. Assembly of the Cylinder Head: Mineral Oil
Provide new seals.
- Thoroughly clean and degrease the female thread of the cylinder head.
- Moisten the new guide ring 020 with hydraulic fluid and pace it into the threaded short
bushing.
- Moisten a new set of Piston rod packing 021 with hydraulic fluid and insert them into the
cylinder head according to the drawing.
- Equip the cylinder head with a new O-ring 016.
- Equip the short bushing with new seals according to the figure shown in paragraph 2.1.
- Disperse some drops of Loctite No. 243 on the perimeter of the bushing’s thread; then
screw it to the bottom of the cylinder head and tighten it.
- Moisten all seals in the cylinder head with hydraulic fluid.
- Equip the cylinder head with a greased O-ring 016.
- Build a cylinder head mounting group. Carefully fit the complete cylinder head to the single
mounting group (piston rod with piston).
Do not damage the cylinder head seals with the piston rod thread.
4.4. Assembly of the Cylinder Head: Phosphate Ester Fluid

Provide new Viton seals.
- Follow the procedures described in the "Mineral oil", refer to the chapter 4.3.
- However, the threaded bush must be equipped with seals of corresponding quality. Refer to
the figure 6-2 or to the parts list with picture in the corresponding register.
4.5. Assembly of the Cylinder Head Mounting Group and the Cylinder Tube
- Moisten the inside of the cylinder tube slightly with hydraulic fluid.
- Grease the cylinder tube surface along the entire perimeter.
- Grease the piston seal on the outer perimeter.
- Carefully introduce the cylinder head mounting group into the cylinder tube.
- Insert the screws 012 between the cylinder head and the cylinder tube.
- Tighten the screws crosswise. Refer to the Table 6-1 for the corresponding torque.
- Pre-assemble the angular screw plug 040, but do not tighten it.
4.6. Pre-assembly of the Cylinder Bottom

- Equip the cylinder bottom with a greased O-ring 016.
- Equip the cylinder bottom with a straight 041 or an angular screw plug 040, depending on
the type of actuator.
Register 6.1
- Introduce the hydraulic tube 042 into the screw plug and tighten it.
4.7. Assembly of the Cylinder Bottom and the Cylinder Tube

- Grease the cylinder tube surface along the entire perimeter.
- Carefully introduce the cylinder bottom into the cylinder tube and simultaneously introduce
the hydraulic tube into the angular screw joint on the cylinder head.
- Insert the screws 011 between the cylinder bottom and the cylinder tube.
- Tighten the screws crosswise. Please see Table 1 for the appropriate torque.
- Tighten the angular screw joint 040.
- Screw in and tighten the locking screw 010.
Tab. 6.1-01: Recommended Torque Values of Screws
Type of Cylinder Screws / Mat. Torque Comment

GHZ-50/20-… V M8 x 30 / DIN 912 8.8 24 Nm Slightly greased
Register 6.1
5 Fitting Instructions for Individual Components Installation
Insert piston into the device. Snap in the main seal according to Fig. 2.
Moisten lightly the main seal and introduce it
to the piston as shown in Fig. 1
The main seal is full sitting in the groove. Snap in the angular guide rings.
Remove the piston off the device. The seal set is completely installed.
Fig. 6.1-04: Fitting the Individual Piston Seal Components
Register 6.1
INSTALLATION AND RETIGHTENING OF "GARLOCK 9000 EVSP"
PACKING RINGS
1. Be sure that the packing spacer/ bearing bush or ring is installed and fully seated in the
bottom of the annular groove between the bonnet and the valve stem.
Do not use a pointed tool to install the packing as damage to the sealing
capability of the packing will result.
2. Lubricate the inside diameter of the packing set with the recommended lubricant in Table
"Recommended lubricants".
3. The GARLOCK 9000 EVSP packing is supplied from the packing vendor as a pre-
packaged 7-ring set, to be installed as shown in the Figure. The set consists of two (2)
lattice-braided end rings, two (2) high-density Graph-Lock adapter rings and three (3) low-
density Graph-Lock sealing rings.
4. Install the bottom braided ring and all the Graph-Lock rings. Place each ring with the
opening 90deg to the opening on the previous ring.
5. The top-braided ring is not installed at this time. Using the packing follower or gland bush,
compress the packing far enough to enable the top-braided ring to be installed in the
packing box. Install the top braided ring.
6. Slide the packing follower or gland bush over the plug stem until it is seated on the packing
set.
Register 6.1
7. Install the packing flange and nuts. Are three threaded bolts for tightening of the packing
installer, make sure that they are fully screwed to the bottom of the threaded holes of the
bonnet.
8. Torque the nuts to the recommended "optimum sealing" torque from Table "Table of
torques". Once the "optimum sealing" torque has been applied to the packing set, it may
then be reduced to the value shown for "optimum operability" in applications where
minimum packing friction is critical, and where the system pressure allows.
Tab. 6.1-02: Recommended Lubricants
RECOMMENDED LUBRICANTS
Parts Lubricant
Dow Corning 111
For Packing and Seals:
Bostik NS-160
Register 6.1
Tab. 6.1-03: Table of Packing Nut Torques
PACKING NUT TORQUE FOR GARLOCK 9000 EVSP PACKING

STEM BOLT OPTIMUM OPTIMUM SYSTEM
SIZE SIZE SEALING OPERABILIT PRESSURE
(in) (mm) (in) (mm) (ft-lbs) (Nm) (ft-lbs) (Nm) (psi) (bar)
14 19 9 12.2 < 2500 170
16 21.6 11 14.9 < 3000 200
5/8 16 5/8 - 11 M 12 19 25.6 13 17.6 < 3500 250
21 28.3 21 28.4 < 4000 275
24 32.4 24 32.4 < 4500 310
24 32.4 16 21.6 < 2500 170
28 37.8 18 37.8 < 3000 200
1 25.40 3/4 - 10 M 16 32 43.2 21 43.2 < 3500 250
37 50 37 50 < 4000 275
41 55.4 41 55.4 < 4500 310
42 56.7 28 37.8 < 2500 170
50 67.5 33 44.6 < 3000 200
1 – 1/2 38.10 3/4 - 10 M 16 58 78.3 39 52.7 < 3500 250
67 90.5 67 90.5 < 4000 275
75 101 75 101 < 4500 310
78 105 52 70.2 < 2500 170
92 124 61 124 < 3000 200
2 50.80 7/8 - 9 M 20 108 145 71 145 < 3500 250
122 164 122 164 < 4000 275
138 186 138 186 < 4500 310
Register 6.1
INSTALLATION AND RETIGHTENING OF "GRAPHITE" PACKING RINGS
This instruction is only valid if the original CCI AG spare parts are used!
1 Assembly of new GRAPHITE Packing Rings

1. Check whether studs (023) have been completely screwed in, retighten them if necessary.
2. Grease screw threads and nuts (024) according to instructions.
3. Determine reference dimension X by measuring the total length X1 and the compression
gland depth X2.
Kontrollmass X ermitteln (e).tif
Fig. 6.1-05: Reference dimension X (X1-X2)

4. Insert ring or guide bushing, packing rings, compression gland, gland and – if available –
lantern ring according to the related drawing.
5. Apply locking washers (025), tighten nuts (024) by hand until compression gland (013)
seats fully on packing rings. Make sure, when mounting the gland (014) and while
tightening its screw joint, that the gland is always parallel to the valve surface. (see fig.
"Compression gland components")
The reference dimension "X" has to be ±0.5 mm.
Register 6.1
6. Equally tighten nuts with wrench. The compression of the packing requires 8%* of the un-
pressed packing height. After the screw joint has been tightened, you have to check that
there is an equal (concentric) annular clearance between the spindle (010) and the through
borehole in the gland.
7. Check the pressing of the gaskets according to table "Assembling and retightening of
GRAPHITE packing rings" by measuring the reference dimension X before and after the
tightening.
8. Bend lugs of locking washers (025).
If studs or threaded bolts (023) are used, these have to protrude from the
nuts by minimum 2 thread turns.
After the packing rings have been assembled or exchanged, these

have to be checked for leakages after the valve has been commissioned, and
if they are leaky, they have to be retightened according to chapter 2.
Fig. 6.1-06: Compression Gland Components
Register 6.1
2 Retightening of GRAPHITE Packing Rings
If the packing leaks although it was pressed according to instructions or if it has become leak
due to wear during operation, the packing has to be gradually retightened as follows:
The packing heights can be seen in table "Assembling and retightening of GRAPHITE packing
rings."
1. Retighten packing by 0.4%* with respect to the unpressed packing height and check the
annular clearance between spindle and through borehole in gland for concentricity.
2. Wait 3 minutes.
3. Check for leakage.
4. If necessary, repeat procedure.
If no leakage is found anymore, the packing will be retightened once more by 0.4%*.
The whole retightening travel must not exceed 2%* of the un-pressed packing height.
The packing may only be retightened as much as is necessary.
Excessive retightening only causes an inadmissibly high spindle friction
without improving the tightness.
If no sufficient tightness of the compression gland is reached by retightening, all packing rings
have to be replaced.
Tab. 6.1-04: Assembling and retightening of GRAPHITE packing rings
Unpressed total Compressing of:

Height of the
height Packing with 4 packing rings
packing rings
of GRAPHITE
in: 8% 2% 0.4%
packing
mm inch mm inch mm inch mm inch mm inch
8 0.315 32 1.259 2.6 0.10 0.6 0.025 0.13 0.005
10 0.394 40 1.575 3.2 0.13 0.8 0.03 0.16 0.006
12.5 0.492 50 1.968 4 0.16 1 0.04 0.2 0.008
Packing with 6 packing rings
mm inch mm inch mm inch mm inch mm inch
8 0.315 48 1.889 3.5 0.14 1 0.04 0.2 0.008
10 0.394 60 2.362 4.8 0.19 1.2 0.05 0.25 0.01
12.5 0.492 75 2.953 6 0.24 1.5 0.06 0.3 0.012
Register 6.1
FAULT FINDING AND RECOMMENDED REPAIR FOR VALVES AND ACTUATORS
If assembly and maintenance procedures on CCI AG control valves and hydraulic actuators are
observed as described in operating manual, no problems will occur during operation.
The following table below identifies potential problems, possible causes and recommended
repairs.
Tab. 6.1-05: Fault Finding and Recommended Repair
Problem Possible Cause Recommended Repair

Packing incorrectly Compress packing acc. to operating
1
compressed manual
Packing damaged or
Gland Packing 2 Replace packing acc. to operating manual
incorrectly installed
Leakage
Disassemble valve and inspect stem,
Valve stem scratched 3 replace stem if needed. Reassemble valve
with new packing
Cover bolts incorrectly
Cover Gasket 4 Tighten cover bolts acc. to specification
tightened
Leakage
Cover gasket damaged 5 Replace cover gasket
Stem is not enough
Existing system pressure in actuator too
pressed against seat by 6
low
actuator
Valve Seat
Incorrect calibration of
Leakage 7 Check closing signal of positioner
positioner loop
Disassemble valve and rework seat
Damage to seat 8
sealing surfaces
Malfunction of actuator 9 Check control unit and system pressure
Valve Stroke Incorrect calibration of
10 Check positioner loop
does not follow positioner loop
Input Signal
Disassemble valve and make stem easy
Stem is hard to move 11
moving
Damaged seals 12 Replace corresponding seals
Actuator
Leakage Bolted connections loose Tighten or replace bolted connections
13
or damaged respectively
Register 6.1
LIST OF FIGURES REGISTER 6.1
FIG. 6.1-01: EXPLODED VIEW GHZ / GHZ-F ACTUATORS 3

FIG. 6.1-02: GHZ PISTON ROD GASKET, DESIGN FOR "MINERAL OIL" 4
FIG. 6.1-03: GHZ-F PISTON ROD GASKET, DESIGN FOR "PHOSPHATE ESTER FLUID" 5
FIG. 6.1-04: FITTING THE INDIVIDUAL PISTON SEAL COMPONENTS 9
FIG. 6.1-05: REFERENCE DIMENSION X (X1-X2) 13
FIG. 6.1-06: COMPRESSION GLAND COMPONENTS 14
LIST OF TABLES REGISTER 6.1
TAB. 6.1-01: RECOMMENDED TORQUE VALUES OF SCREWS 8

TAB. 6.1-02: RECOMMENDED LUBRICANTS 11
TAB. 6.1-03: TABLE OF PACKING NUT TORQUES 12
TAB. 6.1-04: ASSEMBLING AND RETIGHTENING OF GRAPHITE PACKING RINGS 15
TAB. 6.1-05: FAULT FINDING AND RECOMMENDED REPAIR 16
Register 6.1
REGISTER 6.2:
DISMANTLING & ASSEMBLY OF CCI VALVES
Contents
LP –ISOLATION AND CONTROL VALVE NA 60-700-NB 60-600 2

1 RELEVANCIES 2
LP ISOLATION VALVE NA 60-700 4

1 GENERAL NOTES 4
2 DISMANTLING 4
3 ASSEMBLING 8
4 LAPPING OF VALVE SEAT 10
5 ELECTRICAL CONNECTIONS 10
LP – CONTROL VALVES TYPE NB 60-600 11

1 GENERAL NOTES 11
2 DISMANTLING 12
3 ASSEMBLY 16
4 LAPPING OF VALVE SEAT 18
5 ELECTRICAL CONNECTIONS 18
Register 6.2
Dismantling & Assembly of CCI Valves Page 1 of 19
LP –ISOLATION AND CONTROL VALVE NA 60-700-NB 60-600
1 Relevancies
1.1. Relevant Drawings

Top assembly drawing: 202787-1CH
Fig. 6.2-01: Double Valve NA 60 / NB 60
Register 6.2
1.2. Relevant Instructions in other Registers
- "Revisions Intervals for CCI AG Valves"
- "Cleaning Instructions"
- "Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG / SULZER
Valves".
1.3. Relevant Instructions in this Register

- "Installation and Retightening of GARLOCK 9000 EVSP packing rings".
illustrations will not always correspond exactly to a particular valve. For further information
to a single position please consider the corresponding drawing and parts list.
For security reasons and on account of the weight, suitable tools and means
of transportation must be used when individual parts are handled and
relocated.
Register 6.2
LP ISOLATION VALVE NA 60-700
1 General Notes
- The valve must be depressurized, allowed to cool down to ambient temperature and
drained.
- All electrical wires and cables must be de-energized.
- The piping system to pneumatic actuators must be depressurized.
- Pneumatic actuator, Instructions for Dismantling and Assembly.
equipment from all electric power lines.
1. When several valves are dismantled at the same time, care must be taken that the parts from
2. Prior to assembly, all parts are to be cleaned and inspected for possible damage.
3. When assembling, use only new gaskets.
4. Bolted connections must be done as described in the general maintenance instructions.
The tightening torques for bolts and nuts are given in the corresponding
drawings, mounting instructions or spare parts lists. The tightening torques
applies to correctly lubricated bolts and nuts at room temperature.
2 Dismantling
2.1. Dismantling the Actuator Unit

Disassembly of the actuator-yoke assembly is required. Please refer to the instruction in the
Register "GENRAL MAINTENANCE INSTRUCTIONS":
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring
- Section 1 "Removing the complete actuator unit"
Pay attention to prevent the actuator unit from slipping out!
2.2. Expanding the stuffing Box

1. Bend back the locking plate tabs 016, then loosen and remove nuts 017.
2. Remove the gland flange 011 and scraper ring, if fitted, and pull the gland bush 010 out.
Register 6.2
NA 60.tif
Fig. 6.2-02: NA 60 with actuator unit
2.3. Dismantling the Valve Insert

1. Mark the position of the bonnet 005 relative to the valve body 001.
2. Screw two eyebolts M18 into two opposed tapped holes of the bonnet (Yoke fixation).
Fasten lifting gear to the eyebolts.
3. Pull carefully the plug unit 006/ 009 into the back seat, to the bonnet, and secure against
moving.
4. Lift carefully, using lifting gear, the valve insert complete: the bonnet and the inlet cage
together with the plug unit off the valve body.
Take care not to scratch and bend the valve stem or damage the mating
surfaces of any parts.
5. Never attempts take out the valve seat.
The seat is shrink-fitted!
6. Loosen and remove the plug unit clamp.

7. Carefully separate the plug unit from the bonnet 005.
Register 6.2
Fig. 6.2-03: NA 60 Valve Insert
2.4. Separation of the Inlet Cage from the Bonnet

1. Loosen and remove the socket head screw 048.
2. Carefully remove the inlet cage 007 from the bonnet 005.
3. Thoroughly clean all parts and check them for damage.
4. Inspect the seating surfaces of the valve stem and valve seat for damage. If necessary, re-
lap the seat and plug, in case of major damage re-grind them.
2.5. Dismantling the gland

1. Remove the packing spacer, if necessary. Use a bar stock of the same diameter as the plug
stem (see Figure "Packing removal"). An air blast is usually helpful in removing all loose
material.
Register 6.2
Fig. 6.2-04: Packing Removal
Do not to damage the packing box!
2.6. Plug Unit
The valve stem and plug are tack welded!

NEVER DIVIDE THE PLUG FROM THE VALVE STEM!
Fig. 6.2-05: Plug Unit

- Thoroughly clean and check the plug unit for damages.
Register 6.2
3 Assembling
Apply lubricant to the all studs, bolts, nuts and washers as well as to threaded holes of the
valve, in accordance with the "GENRAL MAINTENANCE INSTRUCTIONS".
DO NOT LUBRICATE THE INSERT PARTS WITH ANY GREASE!
Apply pure Graphite or Molybdenum-Disulphide powder to all surfaces
which have metal-to-metal contact.
In case previously dismantled:

- Install packing spacer and lower it to the bottom of the bonnet stuffing box.
- In case of prior removal of studs and threaded studs, install them in accordance to the
General Maintenances Instructions: "Instructions for Bolt Thread Lubrication and Torque
Settings". Make sure, that they are fully screwed to the bottom of the threaded holes.
- Place the position cylindrical pin into the bonnet, if provided.
3.1. Assembling the Valve Insert (Pre-assembly Work)
Carry out this work in a clean work area.
1. Place the bonnet with his top side down.

2. Using lifting gear place the inlet cage onto the bonnet.
Pay attention of correct situation of the drillings in the inlet cage versus the
tapped holes in the bonnet!
3. By assembly of the inlet cage 007 together with the bonnet 005, screwed with the bolts 048,
prepare an assembly group.
4. Tighten the bolts 048 using the method and pattern described in the "GENERAL
MAINTENANCE INSTRUCTIONS", with torque specified in the Top assembly drawing.
5. Insert carefully the plug unit into the above mentioned assembly group, Slide it carefully
onto its back seat, to the bonnet. Use the spacer 012 as a centring device.
6. Secure the plug unit against moving.
3.2. Inserting the Valve Insert

1. Make sure that the prepared valve insert is ready at hand.
2. Insert a new graphite packing ring 019 into the valve body groove.
3. Screw two eyebolts M18 into two opposed tapped holes of the valve insert (Bonnet-Yoke
fixation). Fasten the valve insert complete to a lifting gear.
4. Check whether contact surfaces of valve insert and valve body as well as sealing surface of
plug unit, are clean and without any damages.
5. Carefully insert the assembled unit, into the valve body.
Observe the mark "bonnet – valve body"!

Never rotate the bonnet while resting on the packing ring!
Register 6.2
6. Restore the nuts / bolts connection between the bonnet and valve body. Tighten the nuts /
studs using the method and pattern described in the "GENERAL MAINTENANCE
INSTRUCTIONS", with torque specified in the Top assembly drawing
7. Using a feeler gauge, check that the bonnet has metal-to-metal contact with the valve body.
If not, re-tighten the packing rings until contact is achieved. Re tighten the bolts to the
required torque.
8. Loosen the stem clamp and lower it slowly onto the valve seat.
Never rotate the plug unit while resting on the valve seat!
Otherwise the sealing surfaces of the stem and seat may become damaged.
3.3. Assembling the Gland

1. Have a set of new packing rings ready at hand.
2. Make sure that the packing spacer 012 is in place and lowered to the bottom of the bonnet
stuffing box.
3. For further procedure as well as concerning assembling, compressing packing rings and
tightening the nuts, see instructions "Installation and Retightening of "GARLOCK 9000
EVSP" packing rings ".
3.4. Assembling the Actuator Unit and Setting of the Valve Stem
1. Apply lubricant to the bolted connection between yoke and valve body, according to the
"Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG / SULZER
Valves".
2. Fit the oil drip pan, if provided.
3. Assembly of the actuator-yoke assembly is required. Please refer to the instruction in the
- Hydraulic actuator GHZ(F), ASM(F) or GHZ with pressure spring.
- Section 2 "Assembly the complete actuator unit and setting of the valve stem".
Register 6.2
4 Lapping of Valve Seat
1. Dismantling the bonnet and valve stem is done acc. to section 2.
2. Apply lapping paste. Using lifting gear, carefully insert the assembled valve stem unit 010
into the valve body. Lower the stem slowly into the valve seat. If the valve is installed
horizontally, bolt the bonnet on using at least 3 bolts, in order to make sure of metal-to
metal contact.
3. Repeat lapping and blue ink testing until the required result is achieved.
4. Thoroughly clean all parts and check them again for damage.
5. Assembly is done according to Par. 3.
5 Electrical Connections
- Re-make all electrical connections.
- Check that the direction of actuator movement is correct.
- Check the position transmitter and re-adjust if necessary.
- Carry out a functional test.
Register 6.2
LP – CONTROL VALVES TYPE NB 60-600
1 General Notes
- The valve must be depressurized, allowed to cool down to ambient temperature and
drained.
- All electrical wires and cables must be de-energized.
- The piping system to pneumatic actuators must be depressurized.
equipment from all electric power lines.
- When several valves are dismantled at the same time, care must be taken that the parts from
- Prior to assembly, all parts are to be cleaned and inspected for possible damage.
- When assembling, use only new gaskets.
- Bolted connections must be done as described in the general maintenance instructions.
The tightening torques for bolts and nuts are given in the corresponding
drawings, mounting instructions or spare parts lists. The tightening torques
applies to correctly lubricated bolts and nuts at room temperature.
illustrations will not always correspond exactly to a particular valve. For further information
to a single position please consider the corresponding drawing and parts list.
For security reasons and on account of the weight, suitable tools and means
of transportation must be used when individual parts are handled and
relocated.
Register 6.2
2 Dismantling
NB 60-allgemein.tif
Fig. 6.2-06: NB 60 with Actuator Unit
2.1. Dismantling the Actuator Unit

Disassembly of the actuator-yoke assembly is required. Please refer to the instruction in the
- Section 1 "Removing the complete actuator unit".
Pay attention to prevent the actuator unit from slipping out!
Fig. 6.2-07: NB 60 Assembly
Register 6.2
2.2. Dismantling the Valve
Always secure all parts of the valve insert against slipping out!
- Remove the oil drip pan from the valve stem, if provided.
2.3. Expanding the Stuffing Box

1. Bend back the locking plates 039, loosen and remove the nuts 038.
2. Remove the gland flange 030 and the gland bush 029.
2.4. Removing the Bonnet

1. Push slowly the plug unit 028/025 into the valve seat and secure against moving.
2. Secure the bonnet 024, using eye bolts and sling, to lifting gear. Refer to the Figure
"Bonnet removal and assembly".
3. Loosen and remove the nuts/ bolts connection between the bonnet 024 and valve body,
using the method and pattern described in the "GENRAL MAINTENANCE
INSTRUCTIONS".
4. Lift out the bonnet assembly using forcing bolts, if provided.
Remove the forcing bolts, if necessary.
Fig. 6.2-08: Bonnet Removal and Assembly

5. Carefully remove the bonnet assembly, over the plug stem, from the valve body using eye
bolt and a lifting gear. Refer to the Figure "Bonnet removal and assembly".
Be sure, that the valves insert remains in the valve body.
Register 6.2
Take care not to scratch and bend the valve stem!
6. Remove the packing set using the packing removal tool, see Figure "Packing removal".
Fig. 6.2-09: Packing Removal
Do not to damage the packing box!
2.5. Removing the Valve Insert
DO NOT LET THE BOLTS OR ANYTHING FALL INTO THE VALVE!

One may close the inlet hole with plugs or tape, so nothing can fall down.
1. Pull slowly the plug unit into the back seat and secure against moving.
Fig. 6.2-10: Valve Insert or Seat Lifting or Inserting Arrangement

2. Remove carefully the upper packing ring off the valve.
Avoid scratches and damages to the valve body-fit!!
Register 6.2
3. Remove carefully, using appropriate means, the valve insert off the valve body. If lifting
holes are provided, attach two eye bolts and a sling. See Figure "Valve insert or seat lifting
or inserting arrangement".
Be careful about the mating surfaces between the plug assembly and the
inlet cage.
Take care do not to scratch the stem with the mounting tool!
Do not damage or bend the valve stem!
4. Separate with care the plug unit from the inlet cage, only if necessary. For this work, we
recommend a clean area.
5. If necessary, carefully pull the valve seat off the valve body as well. Remove the valve seat
using appropriate means; together with the lower packing ring. If lifting holes are provided,
attach two eye bolts and a sling, see also Figure "Valve insert or seat lifting or inserting
arrangement".
Take care not to damage some fits of any parts!

7. Inspect the sealing surfaces of the plug unit and valve seat for damage. If necessary,
recondition seat and stem by lapping, respectively by grinding, in case of major damage.
2.6. Dismantling the Plug Unit
The valve stem and plug are tack welded!

NEVER SEPARATE THE SPINDLE FROM THE PLUG!
2.7. Dismantling the Balance Seal or Packing Ring, if existing
Dismantle the plug assembly only if it necessary!
Fig. 6.2-11: Balance seal

1. Remove the lock wire with pliers.
2. Loosen and remove the studs in accordance to the instruction in "General Maintenances
Instructions", under chapter "Bolt Thread Lubrication and Torque Settings".
3. Separate the retaining ring and the balance seal from the plug.
Register 6.2
5. Inspect the mating and sealing surfaces of the stem/ plug unit and for damage. If necessary,
recondition the stem and the by lapping.
3 Assembly
Apply lubricant to the all studs, bolts, nuts and washers as well as to threaded holes of the
valve, in accordance with the "GENRAL MAINTENANCE INSTRUCTIONS".
DO NOT LUBRICATE THE INSERT PARTS WITH ANY GREASE!
Apply pure Graphite or Molybdenum-Disulphide powder to all surfaces
which have metal-to-metal contact.
In case previously dismantled:

Install packing spacer and lower it to the bottom of bonnet stuffing box.
Place the position cylindrical pin into the bonnet, if provided.
In case of prior removal of studs and threaded studs, install them in accordance to the General
Maintenances Instructions: "Instructions for Bolt Thread Lubrication and Torque Settings".
Make sure, that they are fully screwed to the bottom of the threaded holes.
3.1. Assembly the balance seal
Carry out this work only in a clean work area!
1. Place a new balance seal over the stem on the plug, attach the packing retaining ring and
fasten them with the studs. Tighten the studs by hand. Refer to the Figure "The Balance
Seal".
Take care not to scratch and bend the valve stem with the mounting tools!
2. Place the stem with plug perpendicularly on the soil.
Pay attention to the plug sealing area!
3. Slide using two eye bolts and lifting gear carefully the inlet cage over the plug unit. Pull the
plug unit into the back seat and secure it against moving.
4. Tighten the balance seal studs using the method and pattern described in the "GENRAL
MAINTENANCE INSTRUCTIONS", with the torque specified in the Top assembly
drawing.
5. Lock the studs with steel wire. See the Figure "Balance Seal".
Register 6.2
3.2. Assembly of the Valve
Always secure all parts of the valve insert against slipping out!
When inserting any parts, take care do not to damage the valve seat or any
mating surfaces of the valve.
Before starting work:

- Check the position of the packing spacer and of the position cylindrical pin, if provided.
- Check the valve insert is correctly assembled and plug unit secured against move.
1. Attach carefully a new lower packing ring onto the valve seat.
2. Insert carefully the valve seat complete into the valve body. If lifting holes are provided,
attach two eye bolts and a sling. Make sure that the seat is fully sited in the bottom of valve
body groove. Refer to the Figure "Valve insert or seat lifting or inserting arrangement"
3. Insert carefully and with appropriate means the valve insert into the valve body. If lifting
holes are provided, attach two eye bolts and a sling. See Figure "Valve insert or seat lifting
or inserting arrangement".
4. Make sure, that the inlet cage is fully seated in the annular groove between the valve body
and the valve seat as well the lower packing ring is properly fitted.
Never rotate the inlet cage while resting on packing ring!
5. Loosen the plug clamp and lower it slowly onto the valve seat.
Never rotate the stem/ plug unit while resting on the valve seat.
Otherwise the sealing surfaces of the stem and seat may become damaged.
6. Check whether contact surfaces of bonnet and valve inside are clean, and without any
damages.
7. Install a new upper packing ring 041 to the bonnet.
8. By means of lifting gear attached with care the bonnet, over the plug stem, to the valve
body.
Refer also to the Figure "Bonnet removal and assembly".
Observe the mark and position cylindrical pin into the bonnet, if provided,
versus the bore in the valve body!
Never rotate the bonnet while resting on packing ring!
Do not bend or damage the stem and the mating surfaces!
9. Restore the nuts/ bolts connection between the bonnet and valve body. Tighten them
alternating crosswise in accordance to the "GENRAL MAINTENANCE
INSTRUCTIONS".
10. With a feeler gauge, check that the bonnet has metal-to-metal contact with the valve body.
If not, retighten the lower packing ring until contact is achieved. Re-check the metal-to-
metal contact between the bonnet and the valve body.
11. Restore the nuts/ bolts connection between the bonnet and the valve body in accordance to
the "GENRAL MAINTENANCE INSTRUCTIONS". For the specified torque of the nuts
or bolts refer to the Top assembly drawing.
Register 6.2
12. Recheck metallic tightness between bonnet and valve body with feeler gauge.
13. Remove the sling and eye bolts from the bonnet.
3.3. Assembly the Gland "GARLOCK 9000 EVSP"

1. Have a set of new packing rings ready at hand.
2. In case previously dismantled, install spacer ring 031 and lower it to the bottom of the
packing box.
Do not use a pointed tool to install the packing as damage to the sealing
capability of the packing will result.
3. For further procedure as well as concerning assembling and compressing packing rings,
see instructions "Reconstruction Installation and Retightening of GARLOCK 9000 EVSP
packing rings for CCI AG / Sulzer valves".
3.4. Assembling the Actuator Unit and setting of the Valve Stem
1. Apply lubricant to the bolted connection between yoke and valve body, according to the
"Instructions for Bolt Thread Lubrication and Torque Settings for CCI AG / SULZER
Valves".
2. Fit the oil drip pan, if provided.
3. Assembly of the actuator-yoke assembly is required. Please refer to the instruction in the
- Section 2 "Assembly the complete actuator unit and setting of the valve stem".
4 Lapping of Valve Seat

1. Dismantling the bonnet and valve stem is done acc. to section 2.
2. Apply lapping paste. Using lifting gear, carefully insert the assembled valve stem unit 010
into the valve body. Lower the stem slowly into the valve seat. If the valve is installed
horizontally, bolt the bonnet on using at least 3 bolts or nuts, in order to make sure of
metal-to metal contact.
3. Repeat lapping and blue ink testing until the required result is achieved.
4. Thoroughly clean all parts and check them again for damage.
5. Assembly is done according to Par. 3.
5 Electrical Connections
- Re-make all electrical connections.
- Check that the direction of actuator movement is correct.
- Check the position transmitter and re-adjust it if necessary.
- Carry out a functional test.
Register 6.2
FIG. 6.2-01: DOUBLE VALVE NA 60 / NB 60 2

FIG. 6.2-02: NA 60 WITH ACTUATOR UNIT 5
FIG. 6.2-03: NA 60 VALVE INSERT 6
FIG. 6.2-04: PACKING REMOVAL 7
FIG. 6.2-05: PLUG UNIT 7
FIG. 6.2-06: NB 60 WITH ACTUATOR UNIT 12
FIG. 6.2-07: NB 60 ASSEMBLY 12
FIG. 6.2-08: BONNET REMOVAL AND ASSEMBLY 13
FIG. 6.2-09: PACKING REMOVAL 14
FIG. 6.2-10: VALVE INSERT OR SEAT LIFTING OR INSERTING ARRANGEMENT 14
FIG. 6.2-11: BALANCE SEAL 15
Register 6.2
REGISTER 6.3:
DISMANTLING & ASSEMBLY OF DRAG® VALVES
LP – SPRAY WATER CONTROL VALVE, DRAG® 840H; 202787-2CH
INSTALLATION AND MAINTENANCE INSTRUCTIONS
MODEL 840G/H/TBS & 860G/H/TBS

SERIES CAGE GUIDED AND CAGE RETAINED SEAT
VALVES WITH HYDRAULIC ACTUATOR
FOR VERTICAL MOUNTING
All Part Numbers and Serial Numbers are to be found in the Top Assembly Drawings.
Register 6.3
TABLE OF CONTENTS
SECTION I 3
1.1. Introduction 3
1.2. Principle of Operation 3
1.3. Design Features 6
SECTION II 9
2 INSTALLATION 9
2.1. Introduction 9
2.2. Receiving and Inspection 9
2.3. Storage 9
2.4. Handling 10
2.5. Flushing 10
2.6. Installation 10
2.7. Start-Up and Operation 11
SECTION III 12
3 CONTROL ELEMENT 12
3.1. Disassembly 12
3.2. Assembly 12
SECTION IV 13
4 BODY ASSEMBLY 13
4.1. Disassembly 13
4.2. Assembly 14
SECTION V 19
5 ACTUATOR ASSEMBLY AND HYDRAULICS 19
SECTION VI 20
6 PREVENTIVE MAINTENANCE AND PROBLEM SOLVING 20
6.1. Preventative Maintenance 20
6.2. Problem Solving 20
SECTION VII 22
7 VALVE DRAWINGS AND BILLS OF MATERIAL 22
SECTION VIII 22
8 VENDOR LITERATURE 22
LIST OF TABLES REGISTER 6.3 23
Register 6.3
SECTION I
1.1. Introduction
CCI Control Valves are custom selected to fit application and piping requirements, and to
eliminate the problems of cavitations, noise, erosion, and vibration by effectively controlling
fluid velocity. CCI Control Valves are engineered for easy maintenance, and quick-change
trim, with no screwed or welded seats.
The CCI Control Valve trim is built for long, trouble-free service. The key to good service life
is proper installation and routine maintenance during use.
The key features of a CCI Control Valve are the valve body, which is sized to fit piping
requirements; the cage, which provides velocity control; the body assembly, which includes
the seat ring, bonnet, plug assembly, and bonnet spacer or balance cylinder; the actuator
assembly, which regulates the valve trim; and accessory components and controls selected to
meet or exceed valve performance requirements.
1.2. Principle of Operation
Velocity Control
High fluid velocities through the trim are a principal source of severe service control valve
problems. Cavitations, erosion, high noise, and pipe vibration are typical signs that the fluid
velocities are not being controlled. Velocity control problems are eliminated with multi-staged
Control Valves.
CCI Cage Trim

In some applications, CCI offers custom designed cage trim. The configuration, size, and
quantity of passages in the cage are designed to provide the required flow capacity and valve
characteristic without loss of velocity control (see Figure 1.1).
Fig. 6.3-01: CCI Cage Trim (Figure 1.1)
Register 6.3
Flow Direction: Over-the-Plug / Flow-to-Close
Over-the-plug flow is typically specified for liquid flow applications, or for applications in
which exceptional shutoff is important. When the flow through the control element is over-the-
plug, the flow enters into the valve body, flows through the cage, past the plug, and out
through the seat ring bore. In some applications, the valve trim can be used as a protective
strainer, preventing particles from damaging the seating surfaces of the plug and seat ring (see
Figure 1.2). A tag on the valve body indicates the valve flow direction.
Fig. 6.3-02: CCI Control Valve;

Over-the-plug flow with drilled hole cage and Teflon balance seal (Figure 1.2)
Flow Direction: Under-the-Plug / Flow-to-Open

Under-the-plug flow is typically specified for steam or gas flow applications, or for
applications in which exceptionally low noise or velocity control is important. When the flow
through the control element is under-the-plug, the flow passes up through the seat ring bore
and under the plug, decelerates through the cage, and exhausts through the valve outlet. The
valve trim can be designed to provide very precise outlet velocity control
(see Figure 1.3, 1.4, 1.5).
Register 6.3
under-the-plug flow with contoured plug assembly (Figure 1.3)

under-the-plug flow with multi-step plug assembly (Figure 1.4)
Register 6.3
under-the-plug flow with gasket bonnet seal and long-cage (Figure 1.5)
1.3. Design Features

The CCI Control Valve features five major elements: the valve body, the disk stack or cage,
the bonnet assembly, the plug assembly, and the actuator and controls assembly. The bonnet
assembly includes the seat ring, bonnet spacer or balance cylinder, bonnet, plug assembly,
seals, and packing seals. The plug assembly includes the plug and stem, or spindle. The
actuator is bolted to the yoke, and the yoke is clamped or bolted to the valve bonnet.
All CCI Control Valve trim components are designed for quick change and long life. Screwed
and welded seat rings are not fitted. The bonnet seal style, plug assembly style, and plug seal
style are selected to suit the application and service requirements.
Bonnet Seal Design

- Gasket Seal
This seal type is used primarily in smaller control valve sizes and in high temperature service.
The pressure boundary seal is obtained by compressing a gasket seal between the bonnet and
body. The gasket seal is manufactured from several layers of stainless steel and graphite that
are wound in even spirals around the axis of the gasket seal. The compressed graphite provides
excellent sealing. The stainless steel supports the graphite, and provides resilience to
temperature changes (see Figure 1.3, 1.4, 1.6). CCI has over 20 years of experience in high
temperature, high-pressure service with this proven design.
Register 6.3
Plug Assembly and Plug Seal Design
- Unbalanced Plug Assembly
The unbalanced plug is typically selected for very small plug sizes, when large actuator
loading is not required to either lift or seat the plug. This design does not feature balance holes,
balance seals, or pilot trim. The unbalanced plug provides exceptional shutoff in the flow over-
the-plug configuration, since the shutoff pressure acts to close the valve.
- Balanced Plug Assembly
The balanced plug design is used to reduce actuator loading. Axial holes are drilled through
the plug or spindle. A seal is placed at the top of the plug, isolating the bonnet cavity above the
plug from the upstream pressure. The axial holes in the plug balance the pressure above and
below the plug, greatly reducing the loading required to lift the plug.
Pressures energized seals, manufactured from materials such as Teflon, are used in lower
temperature services. In higher temperature services, graphite-based balance seals are used. In
some applications, a piston ring is used as a balance seal.
- CCI Pressurized Seat Plug Assembly
The CCI Pressurized Seat Plug Assembly is used in high temperature service requiring tight
control valve sealing. The CCI Pressurized Seat Plug Assembly provides the shutoff of an
unbalanced plug with the low actuator force requirements of a balanced plug.
The CCI Pressurized Seat Plug Assembly features a pilot plug, a main plug, and a piston ring
balance seal. The piston ring allows a small, controlled leak of pressure from the valve inlet to
the bonnet cavity (see Figure 1.6).
When the control valve is closed and the pilot plug is seated, the Pressurized Seat Plug
Assembly provides exceptional shutoff. The shutoff pressure builds in the bonnet cavity above
the plug, acting to close the valve. The actuator needs only to provide sufficient thrust to seat
the pilot plug against the pilot seat in the main plug.
When a signal to open the control valve is received, the actuator lifts the stem, opening the
pilot seat. The pilot rapidly exhausts the bonnet cavity pressure. The plug assembly is now
balanced. As the stem continues to move in the opening direction, a shoulder on the stem
engages a retaining plate on the main plug. The stem lifts the main plug off the main seat. The
actuator needs only to provide sufficient thrust to lift the balanced plug.
Register 6.3
Fig. 6.3-06: CCI Valve with Pressurized Seat Plug Assembly (Figure 1.6)
Register 6.3
SECTION II
2 Installation
2.1. Introduction
This section describes recommended procedures for receiving, storing, handling, and installing
CCI control valves. Good general practice should be used for all maintenance and installation
activities. All applicable regulations and specifications should be followed.
Every CCI control valve is custom designed for a specific application and a specific set of
operating conditions. The control valve drawing provides complete information on valve
design conditions, dimensions, weight, and general arrangement. A nameplate attached to
every control valve lists the design conditions for that particular control valve.
2.2. Receiving and Inspection

a) Shipping and packing documents are attached to or packed in the control valve container.
Quality assurance documents, operation and maintenance manuals, and drawings are
typically packed in the container.
THESE DOCUMENTS SHOULD BE IMMEDIATELY DELIVERED TO THE
APPROPRIATE PLANT MANAGER, PROJECT MANAGER, OR ENGINEER.
b) The container is marked with instructions for handling and storage. These directions should
be strictly followed. Unless specifically required by contract, CCI products are packaged
for domestic shipping and indoor storage.
The control valve is very heavy.
If the valve is not handled properly, serious injury can occur.
Suitable lifting equipment must be properly used and attached.
c) After the shipping container is unloaded at the site, the container should be inspected for
damage. Joints and seams should be inspected for signs of separation.
d) Unless the container is damaged, it should not be opened until the control valve is required
for installation. In order to inspect the valve, the container lid can be safely removed
without reducing the structural integrity of the container. If damage to any parts is
suspected, carefully check the equipment against the packing list. Make a note of any loose,
damaged, or missing parts. Notify both the freight company and your CCI contract
administrator.
2.3. Storage
a) The control valve may have been shipped either disassembled, or with spare parts. Valve
trim parts, including plug assemblies, seat rings, disk stacks, cages, spacers, and balance
cylinders should be coated with rust inhibitor, and placed in a separate container. Seat ring
and plug seating surfaces should be protected with tape. These protective coverings are
removable. Desiccant should be added to the container, and replaced periodically.
b) If the control valve was shipped completely assembled, a desiccant should be added to the
container, and replaced periodically.
Register 6.3
c) All parts or the control valve should be stored in a fire resistant, weather-tight, and well-
ventilated building. The parts should not be exposed to temperatures below -20° F (-29° C)
to 120° F (48° C). The storage area should be safe not be subject to flooding. The floor
should be paved or similarly level, firm, protected, and well drained. All parts should be
placed on pallets or shoring to permit air circulation.
d) To avoid elastomer deterioration, both pneumatic and hydraulic actuators must be cycled at
least every six (6) calendar months. A minimum of three (3) full strokes is required using
the normal operating media.
2.4. Handling
The unit is shipped in a container designed to support both the body assembly and the actuator
assembly. To remove the control valve from the shipping container, place appropriate slings
and lift with a hoist.
Carefully wrap the sling around the valve yoke or operator.
Applicable codes, regulations and industrial practices for handling (hoisting and lifting) loads
must be followed. These include but are not limited to the following precautions:
a) Slings should be free of kinks and twists.
b) Position the lifting hook over the load so that the load does not swing when lifted.
c) The operator shall see that the load is well secured and balanced.
d) The operator shall see that the slings are not handled on the winch head without the
knowledge of the operator.
e) The operator shall avoid carrying loads over people.
2.5. Flushing
a) When the control valve is installed in a system suspected to be contaminated, the system
should be flushed to prevent possible damage to the control valve. The control valve trim
should not be used during flushing. The control valve trim must be removed prior to
flushing. Remove the actuator assembly and valve trim from the body assembly as
described in Sections III and IV.
b) Flushing trim can be obtained from CCI. Install the flushing trim, complete flushing, and
reassemble the valve as described in Sections III and IV.
For 3-way valve, do not remove control valve trim from body for flushing.
Once 3-way valve is installed in the pipe line, trim components can not be
removed due to its unique design feature. In order to do flushing for 3-way
valve, it shall be done with the valve trim fully open or fully closed as
required by the user intention.
2.6. Installation
a) The control valve has been cleaned, inspected, and sealed at the factory prior to shipment.
Protective covers have been installed in the valve inlet and outlet. These covers prevent the
entry of foreign matter into the valve. No additional cleaning should be required. After the
protective covers are removed, the interior of the body should be inspected in order to
ensure that the valve is free of contaminants. If cleaning is required, refer to Section VI.
Register 6.3
Take care when lifting or handling the control valve to ensure that the
accessories and lines are not damaged.
Do not mar the sealing surfaces of flanged valves.
The heat of post weld heat treatment can damage valve seals. Remove ALL
valve trim PRIOR to welding. The valve may require disassembly if post
weld heat treatment will be performed. In case the valve has to be welded
with its end pipe as a valve assembly, valve position should be open to avoid
possible damage.
Contact CCI for additional instructions.
Do not use the plug, stem, or actuator shafts for grounding during welding
operations.
b) After the control valve has been removed from the shipping container, lift and rotate the
control valve into its installed position using a hoist and sling.
c) The direction flow is indicated by an arrow on the body. The valve must be installed in the
correct flow direction.
d) The control valve is normally installed in a vertical position, with the valve operator
pointed straight up. If the assembly is to be installed in any other orientation, then adequate
supports may be required for the valve operator assembly.
e) Verify that all required utilities are available.
f) Complete the welding or bolting of the valve in line. For welded-end valves, which require
post weld heat treatment, Post-weld Heat Treatment should be completed prior to
reassembly of the valve.
2.7. Start-Up and Operation

Instructions for the assembly, disassembly, and maintenance of the valve operator are provided
in Section V. Drawings for the actuator assembly and for manual override assemblies are
provided in Section VIII. Information on controls, accessories, by-pass valves, and manual
overrides are provided in Section VII.
a) If the valve has been reassembled, verify that the proper assembly technique and bolt torque
has been applied to the valve bonnet studs, packing, yoke connection, and stem connection.
See Sections III and IV for details.
b) Verify that all required utilities, including pneumatic, hydraulic, and electric supplies and
signals, are connected and properly adjusted. Refer to the Top Assembly drawing for
applicable instructions.
c) Verify that all control and accessory components are connected and correctly adjusted.
Refer to the Top Assembly drawing and Section VII for applicable instructions.
d) Clean the actuator shaft of foreign material and inspect all connections for leakage.
Register 6.3
SECTION III
3 Control Element
3.1. Disassembly
Fig. 6.3-07: Control Element with GHZ / GHZF Actuator (Figure 3.1)
3.2. Assembly
- Refer also to the same table for detail of the control element drawings for torque values and
other data applicable to a particular control element.
Register 6.3
SECTION IV
4 Body Assembly
- (Refer to Figure 4-1 for typical construction)
4.1. Disassembly
To avoid personal injury or damage to the system, isolate and relieve the
valve from the system pressure prior to any disassembly.
a) With the actuator, move the valve to 50% open.
Then, remove the stem connector from the stems.
Measure and record the gap between the two stems, for future reference.
b) There are three yoke mounting configurations.
One has several hex bolts holding the yoke to the bonnet, the second has two half clamps
that are bolted together, and the third has a spud nut.
All three designs require that the yoke be placed on the bonnet and aligned to the drawing
requirements before tightening.
There is a set screw on the clamp design that is to be tightened to prevent yoke rotation in
service.
c) Lift the actuator off the valve body assembly, without damaging accessories or tubing.
Fig. 6.3-08: Typical Valve Construction (Figure 4-1)
Register 6.3
d) Slowly relieve all air pressure from the actuator assembly. If an air
accumulator/volume/storage tank is attached to the actuator, this must be safely vented to
the atmosphere.
e) Push the valve stem down, to put the plug on the seat. Loosen the stem packing. Remove
the bonnet nuts, and remove the bonnet from the body, leaving the valve trim in the body.
Remove the plug assembly, cage, seat ring, and the valve gaskets from the body.
f) If the valve is fitted with a "U" shape balance seal, note the orientation upon removal from
the valve. The seal must be replaced in this same direction.
g) Remove the stem packing from the bonnet. (Fig 4.2)
h) Clean each piece, and review for damage. Ensure parts are available for replacement.
Fig. 6.3-09: Packing Removal (Figure 4-2)
4.2. Assembly
Inspect and replace worn parts as needed before reassembly. It is recommended that all soft
goods such as stem packing, gaskets, balance seals, and soft seats be replaced before each
reassembly.
a) If applicable, snap the new soft seat insert onto the seat ring.
b) Apply lubricant (refer to Table 4-3 for suitable selection) to the seat ring gasket and insert
the seat ring gasket, and then the seat ring into the body. (Fig 4.3)
c) Place the lower cage gasket on the body ledge. Insert the cage into the body.
NOTE: If a two-piece cage assembly is used (when the seal is not on the plug), install the
seal between the two cage pieces, with the original orientation. For valves that are flow to
open, the open side of the U faces the bonnet; flow to close valves, have the open side face
the seat ring.
d) Install the plug seal on the plug (if so designed). Install the plug assembly into the cage.
e) Install the upper cage gasket.
Register 6.3
f) Place the bonnet on the valve, and lightly tighten the bonnet bolting.
g) Install the packing as shown in Figure 4-1 (Refer to Figure 4-5 for packing arrangement.).
For graphite packing, install two rings at a time, and compress them to the torque values in
Table 4-2, before adding additional packing.
h) Torque the bonnet bolting, using a cross-body torque pattern (Fig 4-4). Apply only half the
torque value specified on each bolt, before reaching the final torque value. Torque values
are in Table 4-1. Use table 4-1B for stainless steel bolting, used with stainless steel
(unpainted) valves. Table 4-1A applies to carbon steel valve materials.
i) Torque the stem packing to the values in Table 4-2.
j) Apply air to the actuator, moving the stem to about the 50% open position.
k) Place the yoke and actuator to the control valve body, and reconnect the mounting
hardware.
l) Move the actuator stem to the gap measured in step 4.1.b., above. If that was not recorded,
start with a gap of about 5 mm (0.2 inches) of the valve stem, and install the stem
connector.
Tab. 6.3-01: Alloy Steel Bolting (Table 4-1A)
BONNET BOLT TORQUE VALUE RANGES

ANSI 150 and
ANSI 600 ANSI 900 ANSI 1500
300
VALVE SIZE N-m Ft-lb N-m Ft-lb N-m Ft-lb N-m Ft-lb
79- 79-
25 NB 1" 107-119 107-119 79-87 107-119 107-119 79-87
87 87
79- 79-
40 NB 1.5" 107-119 107-119 79-87 107-119 207-229 153-169
87 87
79- 79-
50 NB 2" 107-119 107-119 79-87 107-119 284-314 209-231
87 87
79- 153- 578-
75 NB 3" 107-119 207-229 784-867 784-867 578-639
87 169 639
209- 1043- 770- 1043-
100 NB 4" 207-229 153-169 284-314 770-851
231 1153 851 1153
302- 1128- 832- 1128-
150 NB 6" 207-229 153-169 409-452 832-920
333 1247 920 1247
616- 1128- 832- 1128-
200 NB 8" 284-314 209-231 835-923 832-920
681 1247 920 1247
616- 1487- 1097- 1487- 1097-
250 NB 10" 450-500 330-370 835-923
681 1643 1212 1643 1212
616- 1909- 1408- 1909- 1408-
300 NB 12" 835-923 616-681 835-923
681 2110 1556 2110 1556
350 NB 14" 835-923 616-681 --- --- --- --- --- ---
Register 6.3
m) Stroke the valve from full closed to full open, noting the ends of travel. Adjustment may be
required to achieve the full valve stroke, without going over the required travel. The correct
valve travel is stated on the valve tag. To correct the stroke, rotate the valve stem:
Clockwise to reduce the valve travel, counter clockwise to increase the valve travel.
n) Calibrate the positioner, and check the performance of any other valve-mounted equipment.
Tab. 6.3-02: Stainless Steel Bolting (Table 4-1B)
BONNET BOLT TORQUE VALUE RANGES
ANSI 150 and
ANSI 600 ANSI 900 ANSI 1500
300
VALVE SIZE N-m Ft-lb N-m Ft-lb N-m Ft-lb N-m Ft-lb
93- 68- 68- 93- 68- 93-
25 NB 1" 93-103 68-76
103 76 76 103 76 103
93- 68- 68-
40 NB 1.5" 93-103 --- --- --- ---
103 76 76
93- 68-
50 NB 2" 93-103 68-76 --- --- --- ---
103 76
93- 68- 180-
75 NB 3" 133-147 --- --- --- ---
103 76 199
133- 246-
100 NB 4" 180-199 182-201 --- --- --- ---
147 272
133- 354-
150 NB 6" 180-199 261-289 --- --- --- ---
147 392
182- 730-
200 NB 8" 246-272 538-595 --- --- --- ---
201 806
182- 730-
250 NB 10" 246-272 538-595 --- --- --- ---
201 806
730-
300 NB 12" --- --- 538-595 --- --- --- ---
806
350 NB 14" --- --- --- --- --- --- --- ---
Tab. 6.3-03: Recommended Packing Nut Torques (Table 4-2)
STEM SIZE TEFLON GRAPHITE
mm inch N-m Ft-lb N-m Ft-lb
16 0.63 13 10 24 18
20 0.79 13 10 34 25
25 0.98 20 15 38 28
32 1.26 27 20 54 40
Tab. 6.3-04: Recommended Lubricants (Table 4-3)
Non Nuclear Nuclear

Dow Corning 111 Dow Corning 111
For Packing and Seals:
Bostik NS-160 Bostik NS-160
Register 6.3
Never-seez Never-seez (Nuclear Grade Nickel)
For Bolting:
Felpro Felpro N-1000 or N-5000
Fig. 6.3-10: Lower Gasket Installation (Figure 4.3)
Fig. 6.3-11: Example of Bolt Tightening Sequence
Register 6.3
Fig. 6.3-12: Packing Arrangement (Figure 4.5)
Register 6.3
SECTION V
5 Actuator Assembly and Hydraulics

For detailed information see:
- Register 3: Description of Main Control Components
- Register 4: Electrical & Electro-hydraulic Components
- Register 5: General Maintenance Instructions
- Register 7: Hydraulic Power Unit
- Register 9: Data Sheets & Dimensional Drawings
- Register 10: Assembly Drawings and Parts Lists
Register 6.3
SECTION VI
6 Preventive Maintenance and Problem Solving
6.1. Preventative Maintenance

Every 3 years the stem packing, and if applicable, balance seal and or soft seat should be
replaced. The actuator diaphragm and O-ring should be replaced every 6 years. Other parts are
to be replaced when they show wear, to prevent additional damage to the equipment.
6.2. Problem Solving

Table 6-1 gives some general ideas to solve some typical field problems that may occur during
the lifetime of the control valves. More significant problems should be referred back to the
factory for assistance.
Tab. 6.3-05: Problem Solving (Table 6-1)
PROBLEM CORRECTIVE ACTION

1. Torque the packing flange to the limits specified in Table 4-2.
Check for leakage.
2. If damage to the stem is suspected, go to step 3. Otherwise,
following all site safety precautions, replace the packing. In case
Stem packing leakage
O-rings are installed on the packing follower, check the O-rings
first.
3. Disassemble the valve. Visually inspect the stem and replace the
plug assembly if it is damaged. Also, replace the stem packing.
1. Check the system air supply pressure to the valve.
2. For spring open valves (DA), ensure that the upper diaphragm
pressure is equal to the filter regulator set pressure, to ensure full
Excessive internal shut off.
leakage when the 3. Try to rotate the plug assembly clockwise, while the valve is
valve is shut off seated. This will ensure that the valve is on seat. If unsure, lift
the plug assembly off seat, and rotate 1/4 turn clockwise.
4. Disassemble the valve and check the gaskets, and the plug, and
seat ring (seating surfaces), and the balance seal if so supplied.
5. Cool the valve and torque the bonnet to the limits specified on
the table 4-1.
Bonnet leakage
6. Disassemble the valve and check the parts for damage. Reinstall
the bonnet and torque evenly, as specified in this manual.
Register 6.3
PROBLEM CORRECTIVE ACTION
1. Check the system air supply pressure to the valve and the filter
regulator operation.
2. Check the operation of all the accessories such as volume
Plug assembly boosters.
jumping or sticking
3. Torque the packing flange to the limits specified in table 4-2.
4. Disassemble the valve and check the plug assembly and cage for
galling.
Valve does not follow
2. Check the positioner calibration and performance.
positioner input signal
3. Disassemble the actuator and inspect the diaphragm.
1. Check the valve inlet pressure and flow rate.
Reduced flow through 2. Visually check to see if the valve is responding to the signal.
valve
3. Confirm that the valve is traveling the full rated stroke. Re-
calibrate if full stroke is not reached.
Actuator assembly 1. Check torque on the diaphragm case bolts.

leakage 2. Disassemble the actuator. Replace the diaphragm and o-ring.
2. Torque the packing flange to the limits specified in Table 4-2
Slow stroke time 3. Check the operation of the filter regulator. Clean the positioner
nozzle.
4. Check the adjustments of the accessories such as boosters and
solenoids.
Position overshoot or
hunting at a stroke 2. Check the calibration of the positioner.
position
3. Check that the booster adjustment is not too sensitive.
- ACCESSORY COMPONENTS AND RECOMMENDED SPARE PARTS, ASSEMBLY
DRAWINGS & BILLS OF MATERIAL WILL BE ATTACHED WITH THIS MANUAL
Register 6.3
SECTION VII
7 Valve Drawings and Bills of Material

- For Top assembly with Parts list and Material refer to the Register 10: "Drawings with
Parts List"
Recommended Spare Parts

- Flexitallic Gaskets
- Balance Seal (if applicable)
- Packing
- Packing Spacer
- Packing Follower
- Balance Seal Spacers (if included)
- Metal Seal (if applicable)
- Actuator O-Rings
- Actuator Bushing
These parts are long lead time items:

- Plug Assembly
- Cage Assembly
- Seat Ring
- Piston Rings (if included)
SECTION VIII
8 Vendor Literature
- For corresponding Vendor Literature refer to the Register 09
Register 6.3
FIG. 6.3-01: CCI CAGE TRIM (FIGURE 1.1) 3

FIG. 6.3-02: CCI CONTROL VALVE; OVER-THE-PLUG FLOW WITH DRILLED HOLE CAGE AND
TEFLON BALANCE SEAL (FIGURE 1.2) 4
FIG. 6.3-03: CCI CONTROL VALVE; UNDER-THE-PLUG FLOW WITH CONTOURED PLUG
ASSEMBLY (FIGURE 1.3) 5
FIG. 6.3-04: CCI CONTROL VALVE; UNDER-THE-PLUG FLOW WITH MULTI-STEP PLUG
ASSEMBLY (FIGURE 1.4) 5
FIG. 6.3-05: CCI CONTROL VALVE; UNDER-THE-PLUG FLOW WITH GASKET BONNET SEAL
AND LONG-CAGE (FIGURE 1.5) 6
FIG. 6.3-06: CCI VALVE WITH PRESSURIZED SEAT PLUG ASSEMBLY (FIGURE 1.6) 8
FIG. 6.3-07: CONTROL ELEMENT WITH GHZ / GHZF ACTUATOR (FIGURE 3.1) 12
FIG. 6.3-08: TYPICAL VALVE CONSTRUCTION (FIGURE 4-1) 13
FIG. 6.3-09: PACKING REMOVAL (FIGURE 4-2) 14
FIG. 6.3-10: LOWER GASKET INSTALLATION (FIGURE 4.3) 17
FIG. 6.3-11: EXAMPLE OF BOLT TIGHTENING SEQUENCE 17
FIG. 6.3-12: PACKING ARRANGEMENT (FIGURE 4.5) 18
LIST OF TABLES REGISTER 6.3
TAB. 6.3-01: ALLOY STEEL BOLTING (TABLE 4-1A) 15

TAB. 6.3-02: STAINLESS STEEL BOLTING (TABLE 4-1B) 16
TAB. 6.3-03: RECOMMENDED PACKING NUT TORQUES (TABLE 4-2) 16
TAB. 6.3-04: RECOMMENDED LUBRICANTS (TABLE 4-3) 16
TAB. 6.3-05: PROBLEM SOLVING (TABLE 6-1) 20
Register 6.3
REGISTER 7:
HYDRAULIC POWER UNIT
Contents
HYDRAULIC POWER UNIT HV 350 AHF 2

1 DESCRIPTION 2
2 CONSTRUCTION 2
3 FUNCTION 3
4 ELECTRIC CONTROL SYSTEM 4
5 DESCRIPTION OF FUNCTIONS 4
6 CONSTRUCTION 5
HYDRAULIC FLUID "FYRQUEL EHC" 6

1 AMBIENT CONDITIONS 6
2 HYDRAULIC FLUID 7
3 FILTER CLASSES FOR HYDRAULIC SYSTEMS PER 100 ML TO SAE-ASTM 8
4 VISCOSITY-TEMPERATURE-DIAGRAM FOR FYRQUEL EHC 9
OPERATION AND MAINTENANCE 10

1 OPERATION 10
2 MAINTENANCE 10
COMMISSIONING OF HYDRAULIC POWER UNIT 12

1 FILLING UP 12
2 GAS PRE-PRESSURIZING PRESSURE IN ACCUMULATOR 12
3 FLUSHING 14
ERECTION INSTRUCTIONS FOR HYDRAULIC POWER UNITS HV… AND PIPING 19

1 HYDRAULIC POWER UNIT 19
2 HYDRAULIC PIPES 19
BLADDER-TYPE ACCUMULATOR 28
1 MODE OF OPERATION 28
2 DRAWING & PARTS LIST 29
APPENDIX REGISTER 7 30
1 CJC FLUID TREATMENT UNIT 30
2 FILLING DEVICE OLAER OSP 746 30
10.2011 / Ing Register 7

Hydraulic Power Unit Page 1 of 30
E07_104748-51
HYDRAULIC POWER UNIT HV 350 AHF
1 Description
The hydraulic power unit serves to supply the necessary pressurized hydraulic fluid for the
actuators. The HV 350 AS unit is designed for use in large CCI AG / SULZER hydraulic
systems.
Fig. 7-01: Hydraulic Power Unit HV 350 AS Fyrquel
2 Construction
The hydraulic power unit is equipped with an accumulator to cover peak requirements. The
pump is therefore designed for average consumption only. The Power Unit is equipped with
two motor-pump units (MPA 1, MPA 2), each with an accumulator charging valve, only one
motor pump unit is in operation at a time. The tank has sufficient capacity to allow for
drainage of pipes and actuators into the tank.
A bypass filter unit is mounted on top of the tank. It is self-contained and comprises electric
motor, pump and filter. An air cooler is arranged immediately behind this system. The pump
can also be used to fill and empty the tank by switching over a multi-way cock.

E07_104748-51
The power unit can be fitted with a heating system.
The system noise emission level is less than 75 dB at a distance of one meter
The controller of hydraulic power unit, together with corresponding power switches as well as
operational and display elements necessary for commissioning, is placed in a local control box
located on top of power unit and is a fully-wired component of the unit.
3 Function
See also the hydraulic diagram.
The Power Unit has two pumps and each has its own accumulator charging valve. One pump is
always in operation and the other is stand-by. Every three days the pump in operation is
changed. At start up and at high consumption the stand-by pump is started to help charging the
accumulator.
The internal gear pump (MPA) draws the hydraulic fluid from the tank and pumps it into the
accumulator (SP). As soon as the pressure in the accumulator has risen to the maximum, the
accumulator charging valve (Y341, Y342) switches the pump over to circulation, i. e. the
pump discharges back into the tank through the accumulator charging valve at practically no
pressure.
- A non-return valve prevents the hydraulic fluid from flowing back out of the accumulator.
If the pressure in the accumulator drops by 10 %, the charging valve switches over and the
accumulator will be charged again. A pressure reducing valve (DRV) behind the
accumulator supplies constant, controlled system pressure (P1) to the actuators.
- To feed a stand-by accumulator to a fast stroking system of actuators, a separate connection
(P2) straight after the pump is provided. The required supply pressure is set by pressure
reducing valve (DRV) fitted in the additional unit (ZB2).
In case of excessive temperature rise a fan (FK) is started, and switched off as soon as the
temperature decreases by approximately 5°C.
In case of overheating of the hydraulic fluid or the hydraulic fluid level in the tank is too low,
both motor-pump units are switched off.
If the power unit is equipped with a heating system, the control system switches the heater on
or off, depending on the temperature of the hydraulic fluid.
If the pump fails to charge the accumulator the other pump is automatically started and
switched off as soon as the pressure is normal. After three failures the stand by pump is
changed to operating pump and an alarm is given.
If the accumulator pressure drops too low, an alarm indicates hydraulic power unit failure.
Accumulator and pump are protected by a pressure relief valve (DBV). A second pressure
relief valve (DBV) limits the system pressure (P1).
The gas pre-pressurizing pressure N2 (Nitrogen) of the accumulator is checked with the help
of the charging time.

E07_104748-51
4 Electric Control System
The control system of the hydraulic power unit guarantees correct performance of the pressure
fluid system. Basically, the control system covers the following functions:
- switching of the accumulator charging valve
- automatic starting of the stand-by pump
- automatic change of the operating pump
- safeguarding the hydraulic power unit
- generating alarm and message signals
By design, the control system is subdivided into functional groups, such as the control system
proper, a display and operating section as well as power switches for the Motors.
The control system processes the following signals (4...20 mA):
- LT492 Level transmitter
- PT494 Pressure transmitter
- TT493 Temperature transmitter
Corresponding Function, Connection and Wiring Diagrams are filed in the
register "Electronic Equipment".
5 Description of Functions
5.1. Control of the 2 Main Pumps

- selecting the operating, resp. stand-by pump
- automatic switching over to the stand-by pump when the corresponding controller trips
- temporary parallel operation when "pressure low"
The main pumps are shut down at
- level to low
- temperature to high
5.2. Control of the Filter Pump

- "start" command when a main pump is switched on
5.3. Control of the Fan

- "start" command when filter pump is in operation and "temperature high"
5.4. Control of the Heating

- "start" command when "temperature low"
5.5. Supply
The hydraulic power unit requires a three-phase electrical supply and for the controller a
24 V DC supply.

E07_104748-51
6 Construction
AB Supply manifold SK Control box

BF Air breather filter SP Accumulator
F Connection for filling and draining LT492 Level Transmitter
FA Filter unit TT493 Temperature transmitter
FK Air/fluid cooler with fan PT494 Pressure transmitter
HZ Electric heating (on request) Y341 Accumulator charging valve
MPA 1,2 Motor-pump units Y342 Accumulator charging valve
Fig. 7-02: Design HV350 AS Fyrquel

E07_104748-51
HYDRAULIC FLUID "FYRQUEL EHC"
1 Ambient Conditions
Ambient temperatures: max. 50 °C (limited by motors, solenoid valves)
min. -10 °C (limited by accumulator)
Tab. 7-01: Ambient Conditions Fyrquel EHC
Ambient Temperatures
normal °C 26-35
maximum °C 45
Liquid Temperatures
ideal (30-50 mm ²/s) °C 35-45
min. (300 mm ²/s) °C 14
max. (15 mm ²/s) (switch-off pump) °C 60
min. temp. start (800 mm ²/s) °C 5
Fan switched on (25 mm ²/s) °C 50
Heating switched off (60 mm ²s) °C 33
Remarks:
- The normal ambient temperature has been selected so that the viscosity of the resting fluid
in the pipes does not exceed 100 mm2/s (subsequent to pressure drop).
- Longer stroking times of the actuators must be expected if temperature drops towards the
minimum operating temperature.
- By means of a heating device, the fluid in the power unit can be raised to normal running
temperature. However, this does not necessarily improve the operating conditions of the
actuators.

E07_104748-51
2 Hydraulic Fluid
As hydraulic fluid, a phosphate ester was chosen, which ensures a good fire protection. The
fluid has good lubricating properties and allows a comparatively easy maintenance.
We recommend the use of Fyrquel EHC of the AKZO Chemical Division. This fluid has been
developed for high pressure hydraulic systems.
2.1. Typical Properties

- Specific gravity at 15 °C1.14 kg/dm3
- Pour point -18 °C
- Flash point 235 °C
- Fire point 352 °C
- Auto-ignition temperature 593 °C
2.2. Limit Values of the Fluid Analyses

- Viscosity at 40 ° C 40-48 mm2/s (cST)
- Mineral oil content max. 1 %
- Water content max. 0.15 %
- Acid number max. 0.2 mg KOH/g
- Chlorine content max. 150 ppm
- Resistivity min. 8x 109 Ohm/cm
To guarantee trouble-free operation, contamination must not exceed SAE class 3 (equivalent to
ISO 15/12).

E07_104748-51
3 Filter Classes for Hydraulic Systems per 100 ml to SAE-ASTM
Tab. 7-02: Filter Classes for Hydraulic Systems per 100 ml to SAE-ASTM Classes
Filter class Size of particles in μm

5 to 10 10 to 25 25 to 50 50 to 100 >100
0 2 700 670 93 16 1
1 4 600 1 340 210 28 3
2 9 700 2 680 380 56 5
3 24 000 5 360 780 110 11
4 32 000 10 700 1 510 225 21
5 87 000 21 400 3 130 430 41
6 128 000 42 000 6 500 1000 92
7 to 10 - - - - -
3.1. Resistance of the Sealing Material:

- Resistant against Fyrquel EHC are normally:
- Butyl
- Fluoro-Elastomer (Viton)
- EPDM Ethylene-Propylene-Dien-Caoutchouc
- PTFE (Teflon)
- Polyamide (Nylon)
- Silicone
3.2. Non-resistance
- Natural rubber
- Nitril NBR
- Neoprene CR
3.3. Painting
Most coatings will soften and peel in the presence of Fyrquel. However, certain polyurethane,
two component resin catalyzed epoxy are generally resistant to Fyrquel.

E07_104748-51
4 Viscosity-Temperature-Diagram for Fyrquel EHC
Fig. 7-03: Viscosity-Temperature-Diagram Fyrquel EHC
For the detailed viscosity values, see corresponding hydraulic data sheet in
the register 9.

E07_104748-51
OPERATION AND MAINTENANCE
The hydraulic accumulators are delivered for safety reasons for transport
Before commissioning are all hydraulic accumulators must be filled with
the nitrogen on the nominal charging pressure. The nominal charging
pressures are taken of the hydraulic data sheet in appropriate register.
1 Operation
The hydraulic power units pass a functional test in the works and are delivered ready for
operation (without hydraulic fluid). The plant specific setting values for the monitoring
equipment must be taken from the hydraulic-data sheet.
After commissioning work has been finished, the hydraulic power unit is ready to assume
duty.
The charging time of the accumulator is controlled, and if the charging time is too short an
Alarm N2 is given. The N2 pressure of accumulator should then be checked and recharged if
necessary. For refilling of bladder-type accumulator with nitrogen, see corresponding separate
instruction.
An Alarm is given at low fluid level (about 200 mm) At a level below about 170 mm the
pumps are stopped and the heater switched off, operation is not possible anymore
2 Maintenance
The hydraulic power unit is largely maintenance-free.
2.1. Daily Checks

- Visual inspection of piping system and connections for leakages.
- Read fluid level gauge, thermometer and pressure gauge on the hydraulic power unit.
- Observe clogging indicator on filter housing of the filter unit on the HV. There is a pressure
gauge integrated in the filter housing cover which indicates the degree of contamination. If a
pressure of about 2bar is indicated, the filter element must be replaced. For this Job the filter
unit is to be shut down! After loosening the grip screws on the filter housing, the cover can
be removed and the filter element replaced. Fit cover.

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2.2. During Overhaul of Entire System
- Check condition of the hydraulic fluid: Screw a clean hose onto the minimess connection
(E) on connecting manifold AB and run the other end of the hose into an absolutely clean
receptacle.
When screwing in the hose, liquid starts flowing out! Collect about 1/2 l and
have the hydraulic fluid examined by the supplier!
- Draining: The tank can be emptied with the aid of the filter unit. Establish hose connection
between filter unit and barrel. Move the lever on the filter unit to position I (see type plate)
and start the pump.
- Check accumulator nitrogen pressure and replenish nitrogen, if necessary (see
corresponding separate instruction
- Change the air breather filter on the power unit.
- Check the set points of the monitoring equipment.
2.3. Hoses and Seals

- Rubber is subject to aging, under operating conditions as well as when stored. Duration of
useful life and storage time is, therefore, limited. Hoses and seals should not be stored
longer than 3 years, ideal storing conditions provided, i.e. cool, dry, dark, absence of UV
rays. For this reason, hoses should be checked once every year and immediately replaced if
they are damaged, at the latest, however, after 6 years. Seals must be replaced at each
overhaul.
2.4. Checking of Pressure Set Points

(See Hydraulic Data Sheet for plant specific settings)
- Pressure reducing valve DRV
- Read pressure gauge M1.
- Pressure relief valve DBV
To check DBV loosen locking screw on pressure reducing valve and raise the pressure setting
(by turning clockwise). When the valve starts to open read the pressure gauge M1. The entire
pump capacity will discharge into the tank after pressure raises approx. 3 bars. Set the pressure
reducing valve to the desired value again, tighten the locking screw and check the setting.
2.5. Correction of Settings

- Pressure reducing valves DRV, Pressure relief valve DBV
Loosen the locking screw. Adjust the desired pressure. Turn clockwise for higher pressure and
anticlockwise for lower pressure. Tighten the locking screw and check the setting.
- The pressure relief valve DBV is set to 260 bar, witnessed and sealed by TUeV.

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COMMISSIONING OF HYDRAULIC POWER UNIT
The hydraulic power units pass a functional test in the works and are delivered ready for
operation (without hydraulic fluid).
- When working on the hydraulic system, utter cleanliness must be ensured. Before starting
work, make sure that
- The piping system has been checked for tightness and correct connections.
- Electrical lines are correctly connected and the direction of rotation of the motors
corresponds to the direction indicated by the arrows.
1 Filling Up
- Arrange for hose connection between filter unit and barrel.
- Move lever on filter unit FA to position III (see type plate).
- Switch on pump and fill tank to "MAX." mark on the fluid level gauge. Arrest the lever on
the filter unit in vertical position II.
To achieve trouble free operation, it is mandatory that the hydraulic fluid is
cleaned through the filter loop for at least 12 hours before starting the main
pumps.
2 Gas Pre-pressurizing Pressure in Accumulator

the nitrogen on the nominal charging pressure.
The nominal charging pressures are taken of the hydraulic data sheet in
appropriate register.
2.1. Checking the Gas Pre-pressurizing Pressure

With "OLAER" filling device
- Remove protective cap and valve cap from the gas valve of the accumulator.
- Screw filling device onto the gas valve.
- Close the relief valve (relief valve must be completely closed).
- Screw in the knurled head screw and read off the pre-pressurizing pressure from pressure
gauge.
- If the indicated pre-pressurizing pressure is correct, turn out the knurled head screw and
remove the filling device.
- If the indicated pre-pressurizing pressure is too low, the nitrogen in the accumulator bladder
must be replenished.
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2.2. Inspections after Initial Commissioning
The gas pre-pressurizing pressure in the accumulator must be periodically checked each time
the accumulator is refilled, or the accumulator replaced.
2.3. Inspection Intervals

a) If within 24 hours after replenishing there is no pressure drop noticeable, the pressure must
be checked anew after one week.
b) If the pressure still hasn't changed, the inspection intervals may be extended to 1 month,
then 3 months, finally to 1 year.
2.4. Recharging the Accumulator with Nitrogen

Before charging the hydraulic accumulator, defective gas-valve inserts must be replaced.
Never use automobile tire valves as a substitute!
The accumulator is filled with the aid of the filling device (charging device) which is offered
together with the CCI AG / SULZER list of tools.
001 Charging device 003 Flexible piping

002 Relief valve 004 Pressure gauge
RS Knurled head screw
Fig. 7-04: OLAER Filling Device

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- Remove valve guard and valve cap from the gas valve on the accumulator.
- Mount the filling device onto the gas valve and connect the flexible piping to the nitrogen
bottle.
- Close the relief valve on the filling device (relief valve must be completely closed).
- Open the isolating valve on the nitrogen bottle and let the gas flow into the accumulator
slowly and gradually.
- During the filling procedure, the isolating valve should be closed several times and the pre-
pressurizing pressure read off from the pressure gauge by screwing in the knurled-head
- Excess pre-pressurizing pressure can be reduced by opening the relief valve, i.e. by turning
the lever counterclockwise.
Since the pre-pressurizing pressure changes with the gas temperature, it is
necessary to wait for about 2 minutes after the desired pre-pressurizing
pressure has been attained for the temperature to stabilize. After that, the
pre-pressurizing pressure should be measured again and corrected if
necessary.
- As soon as the pressure gauge indicates the correct pre-pressurizing pressure, turn the
knurled-head screw back and remove the filling device.
- Replace valve cap and protective cap on accumulator and tighten them by hand. Check
tightness by brushing on soap suds.
- Leakages must be rectified on the spot, as, otherwise, the bladder would inevitably be
destroyed.
For more details about OLAER filling device see OLAER Description
OSP 746 in Register "Diagrams, Datasheets & Dimensional Drawings".
3 Flushing
Flushing serves to clean the entire system including the hydraulic fluid and, in particular, the
piping. For this reason, the operating medium must be used for flushing. The "Schnapper" and
the filters or flushing filters required for flushing are part of the flushing equipment which the
CCI AG service man brings with him. If flushing is not to be carried out by CCI AG
personnel, the flushing equipment can be bought or rented.
If there is no flushing equipment available on site the flushing can be carried out according to
the description in chapter 3.5.
All hoses must, at least for some time, be enclosed in the flushing cycle and flushed.
The filter unit must remain switched on during the entire flushing procedure for cleaning the
hydraulic fluid.
Duration of the flushing procedure depends on the length of the piping system and the number
of bends, respectively loops. It must be remembered, however, that the minimum flushing time
for each cycle is 2 hours after minimum flushing temperature has been reached.

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Tab. 7-03: Viscosity
Viscosity class ISO VG 32 46 68

min. 35 45 55
Flushing temperature °C
max. 55 65 75
The filter elements may be loaded up to the maximum permissible differential pressure (check
with fouling indicator on the flushing filter).
3.1. Mounting the Flushing Device
Fig. 7-05: Flushing Device
Fig. 7-06: Flushing Diagram

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- Install flushing device between the T connection on the HPU manifold and the hose of the
return line
- With a hose connect the two L ports of flushing device and HPU
- With a hose connect the SP port on flushing device with the E port on HPU (remove
minimess connector)
- Make sure that there is a filter element in the flushing filter
3.2. Flushing the P- and T-pipes

The illustration shows the connection to the stepping control unit APL. Connections to other
control units are done in a similar way.
For all the actuators being fed by the same piping system:
- Close the ball valve on the P-pipe in front of the actuator.
- Loosen and remove the T-hose from the T-pipe.
- Loosen and remove the P-hose from the control unit and screw it onto the free end of the T-
pipe.
- Open the ball valve on the pressure pipe of the circuit to be flushed.
- Switch on pump motor.
- Set the "Schnapper" on 85 to 90% of the maximum of the accumulator charging pressure.
- Make sure that the accumulator is not being drained.
After half of the flushing time has elapsed, exchange the P-hose for the T-
hose.
Fig. 7-07: Flushing the P and T Lines to the APL

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3.3. Flushing the P- and T-pipes to the Stand-by Accumulator
Close the ball valve on the P-pipe in front of the connecting manifold, fitted on the stand-by
accumulator.
- Loosen and remove the P-pipe from the connecting manifold.
- Loosen and remove the T-hose from the T-pipe and plug the latter up tightly.
- Loosen and remove the T-line from the connecting manifold.
- Connect the P- and T-pipes by means of an angular screw connection.
Fig. 7-08: Flushing the P- and T-pipes to the Stand-by Accumulator
Work on the hydraulic power unit:

Remove the P-pipe to the stand-by accumulator from connection P2 of the additional unit and
screw it onto P1 of the supply manifold.
Screw the corresponding T-pipe from the stand-by accumulator onto connection R of the
"Schnapper".
Flush as described under par. 3.2.
3.4. After Finishing Flushing

Remove the "Schnapper" from the connecting manifold.
Restore the original order of hose connections.

E07_104748-51
3.5. Flushing Without Oil-flushing Kit (Schnapper)
If there is no oil flushing kit on site the flushing can be carried out according to the following
procedure:
- Use as normal the filtration unit to fill the oil from the barrel into the tank.
- Connect the pipes as described in section 3.2 and 3.3.
- Disconnect the T hose from the HPU supply manifold and connect it to the oil barrel.
- Close the ball valve in the pressure line of the circuit to be flushed.
- Switch to auto-operation and wait until the accumulator(s) are charged.
- Open the ball valve and flush the pipes until the pressure drops to P<<.
- Close the ball valve and wait until the accumulator is charged again.
- Repeat the flushing cycle until the tank oil level reaches the minimum indication.
- Stop the motors and fill the oil through the filtration unit back in the tank.
- Repeat the flushing cycle until the minimum flushing cycle time reached.
- Restore the original order of the hose connections after flushing.

E07_104748-51
ERECTION INSTRUCTIONS FOR HYDRAULIC POWER UNITS HV… AND PIPING
1 Hydraulic Power Unit

The location of the hydraulic power unit should be selected so that it is not exposed to direct
sunlight, air circulation around the unit is not impeded, and neither dirt, nor solid parts or water
can drop on it.
The unit must not be arranged a higher level than the servo valve on the actuator at the lowest
level. It is not necessary to bolt the power unit down to the floor.
2 Hydraulic Pipes
2.1. Material for Hydraulic Pipes

2.1.1. Pipes
We recommend clean, scale-free precision tubes to EN 10305-4, quality grade C, seamless
cold-drawn, normal-annealed, of EL35N / Zn 8c acc. to EN 10305-1 and EN 10305-4. If the
pipes cannot be protected from corrosion, stainless steel pipes (material No. 1.4571), seamless
cold-drawn, scale-free, heat-treated acc. to EN 10216-5 to -6, with tolerances to EN10305-1
should be used.
Note: The pipe dimensions, as indicated on the hydraulic diagram, must be adhered to.
2.1.2. Hoses
To prevent transmission of vibration and thermal expansion movements from the steam pipes
to the hydraulic piping system, high-pressure hoses are to be fitted between pipes and control
valves. High-pressure hoses must also be used to join the pipes to the supply manifold on the
hydraulic power unit. The hoses are supplied by CCI AG.
2.1.3. Pipe Couplings
Only high-pressure pipe couplings complying with the provisions of DIN 2353 must be used,
for instance, ERMETO progressive ring high pressure fittings, or ERMETO weld nipple
fittings. In the case of stainless steel tubes, stainless steel progressive rings must be utilized,
for reasons of tensile strength. If the piping is welded, the pipes must be flushed by inert gas.
2.2. Piping
To minimize pressure losses, the pipes between hydraulic power unit and actuator should be as
short as possible and should have as few bends as possible. The pipe connections must be
easily accessible. Leakage piping must be arranged to allow downward flow. The piping must
be erected rigid.
To avoid vibration, the pipes must be fastened approx. every 3 m with pipe clamps (e.g.
polypropylene "Stauff"-clamps, type SM … PP-L1, with support rail, type TS 096, Fig.1). The
pipes must be bent cold.
If they are bent hot, they must, afterwards, be pickled in sections. Pickling must be carried out
by specialized firms.
The pipes must be connected to the control units by means of the high-pressure hoses, supplied
by CCI AG (see Fig. 7-10).

E07_104748-51
To allow for large relative movements, the hoses should be fitted in wide loops.
Erection1.gif
Fig. 7-09: High-pressure Hoses
2.3. Fitting Instructions for ERMETO couplings

For assembly, the relevant instructions of ERMETO are strictly to be followed. When a
standard screw coupling is used, care must be taken that each pipe end is fitted in the same
inner cone with which pre- installation had been carried out.
Assembly Preparations (Preparing the Tubes)
Cut tube off square; de-burr lightly at the EO tube cutting device (AV) makes it easier
internal and external edges. Do not bevel to cut tubes off square
edges.

E07_104748-51
Preparation of Fitting Components
Oil thread and taper of the fitting as well as Slide nut and progressive ring onto the end
EO progressive ring and thread off the nut. of the tube.
We recommend JOKISCH S 101
(molybdenum based) as a lubricant for
stainless steel
Direct Assembly in the Fitting Body

Do not slide progressive ring on backwards! Tighten nut by hand. Press the tube all to
way in to fitting body.
Mark the nut and tube Tighten the nut by approximately 1½ turns
(tube must not turn with nut). When
tightened correctly, the tightening-force
noticeably increases

E07_104748-51
Inspection of Assembly Re-assembly
Loosen nut; check that a visible collar fills out For every re-assembly the nut must be
the space in front of the 1st cutting edge. (It retightened without applying more force than
does not matter if the ring can be rotated on for the first assembly. The fitting body must
the tube end) be firmly held during all assemblies.
Assembly Instructions for Stainless Steel Tubes

Preliminary assembly in the hardened pre-assembly body
(VOMO): Hardened pre-assembly bodies (VOMO) are to
be used for line assembly, assembly of series 400 fittings,
assembly of stainless steel and acid proof tubes to DIN
17440, and BE hose connections (smooth pipe end).
Fig. 7-10: Pre-assembly Body (VOMO)

Assembly in the VOMO permits inspection of the ring cut (visible collar). For line assembly
we recommend: Manual pre-assembly tool HVM-B, or electro-hydraulic pre-assembly
machines.
Note that concerning installation of stainless and acid-proof steel fittings in according to DIN
17440.
Due to the high coefficient of friction, the nut may run on the thread only with difficulty,
particularly with large pipe diameters. We, therefore, recommend taking note of below listed
points:
Prior to assembly, all parts are to be oiled thoroughly. We recommend special purpose oil,
molybdenum based, or, alternatively, castor oil.
Assembly is made easier by loosening, respectively unscrewing, the nut a few times, each time
lubricating the threads anew (this applies, in particular, to pasty or sprayed-on lubricants).
With liquid lubricants, loosening the nut, to allow the lubricant to get between the mating
surfaces, is sufficient.
Important:
Closely follow the assembly instructions and check the visible collar at the
pipe end. Experience shows that with stainless steel tubes, formation of the
collar is less marked than with seamless precision tubes of equal
dimensions.

E07_104748-51
Check the dimensional stability of the tapers Cut tube off square; de-burr lightly inside and
with a taper gauge. outside. (Do not bevel edges)
Select pre-installation body according to tube Slide nut and progressive ring onto tube end
size, and place it in a vice. Oil components. as shown below.
Tighten nut by hand. Press the tubes all the Mark the nut and tube. Tighten nut
way into the pre-installation body. approximately 1 turn (approximately ¼
turns); progressive ring grips tube (tube must
not turn with nut).

E07_104748-51
Final Assembly
Insert pre-assembled tube into fitting body.
Tighten nut approximately ½ turn (Series 400
approximately ¼ turn)
Inspection Re-assembly
The visible thrown-up collar must Each time the nut is unscrewed, it must be
completely fill out the space in front of the retightened without applying more force than
1st cutting edge. for the first assembly. (The fitting body must be
firmly held during all assemblies.)

E07_104748-51
2.4. Fitting Instructions for ERMETO Weld Nipples
erection13.gif
Nut Weld nipple with cylindrical Connection

boss, type SKO
Fig. 7-11: ERMETO-Fitting
1. Cut pipe end square, burr, chamfer for V-welding seam.
2. Slide nut onto weld nipple.
3. Weld the nipple onto tube end as described under par. 2.5.
4. Clean welding on in- and outside.
5. Fit O-ring carefully! O-ring must not be twisted; the weld nipple, tapered end and groove
must be clean.
6. Apply oil to nut, weld nipple, tapered end, and thread before tightening.
7. Screw on nut by hand. Final tightening is done by turning the nut with the spanner by about
1/4 turn. It is important that the pipe with the welded-on nipple is straight and free of stress
when connecting to the transition piece.
2.5. Welding Specifications for Hydraulic Pipes

2.5.1. Material
a) Seamless steel tubes to DIN 2391/C, normalized bright annealed, of quality St 37.4,
material No. 1.0309
- Weld nipple ERMETO type SKO, material No. 1.0401
b) Stainless and acid proof tubes of material No. 1.4571 (X6 CrNiMoTi 17 122), or of
material No. 1.4541 (X6 CrNiMoTi 18 10), to DIN 17458
- Weld nipple ERMETO type SKO, material No. 1.4571
2.5.2. Preparatory Work
- Cut tube off square
- De-burr on in- and outside
- Clean of metal filing etc
- Remove metal filings etc
- When welding on a weld nipple, remove the O-ring and then slide the nut onto the nipple.

E07_104748-51
2.5.3. Welding
- The pipes must be welded according to the TIG process, with the pipes flushed with
forming gas (N2 + H2, approx. 15 % H2), or argon. For pipes 16 x 2, about 2 l/min of
flushing gas are required.
- If possible, welding should be carried out in normal welding position
- The filler wire should have a diameter of 1.2 mm. Materials of pipe and filler wire must
correspond:
Tab. 7-04: Material of Welding Pipes
DMO-JG to Böhler
a) for St 35.4 filler wire: SG MO to DIN 8559
E 70 S-GB to ASME
SAS 4M-JG (stab) to Böhler
b) for X6 CrNiMoTi 17 122 EAS 4M-JG (unstab) to Böhler

and X6 CrNi 18 10 filler wires: SG X 2 CrNiMo 1912 to DIN
ER 316 L to ASME
- air gap i = 1 mm for wall thickness 2 mm and above
- air gap i = max. 0.5 mm for wall thicknesses 1 mm and 1.5 mm
erection14.gif
1) as described 2) Welding using forming gas in piping.

Amount of flushing gas same as per 1)
- Pipes of 1 mm and 1.5 mm wall thicknesses are to be welded with one root layer and a
second layer to fill up the weld seam.
2.5.4. Checks
- A test weld is to be carried out and cut open to see whether it is welded all the way through
- To check the welding for any undue reductions of inner diameter, a steel ball, with a
diameter of 2 mm less than the inner diameter of the pipe, should be run through the pipe
2.5.5. Secondary Treatment
- There is no need for any special after treatment, since the pipes will be flushed prior to the
commissioning of the hydraulic power unit.

E07_104748-51
2.6. Pressure Test
Test pressure = 1.5 x system pressure (P1) of hydraulic piping
- Between hydraulic power unit (HV) and actuator, the pressure test shall be performed with
an external manual pump. (It is not permitted to expose any accumulator or any actuator to
the test pressure.)
- In case it is not possible using an external manual pump, the pressure test can also be
performed with the hydraulic power unit (HV).
2.6.1. Test Procedure
- Multiply pressure P1 by 1.5
- Adjust pressure reducing valve 1 to calculated value. Set pressure relief valve to a value 10
bar higher than the calculated value of 1.5 x P1. Perform pressure testing of hydraulic
piping.
- Following pressure testing, readjust the pressure reducing valve as well as the pressure
relief valve to their normal pressure settings. See hydraulic data sheet.

E07_104748-51
BLADDER-TYPE ACCUMULATOR
1 Mode of Operation
Fig. 7-12: Bladder Operation

E07_104748-51
2 Drawing & Parts List
Item # Parts Name Item # Parts Name

001 Protective cap 005 Bladder
002 Valve cap 006 Fluid port assembly complete
003 Gas valve complete
004 Steel cylinder 200 Seal set
Fig. 7-13: Bladder: Sectional Drawing

E07_104748-51
FIG. 7-01: HYDRAULIC POWER UNIT HV 350 AS FYRQUEL 2

FIG. 7-02: DESIGN HV350 AS FYRQUEL 5
FIG. 7-03: VISCOSITY-TEMPERATURE-DIAGRAM FYRQUEL EHC 9
FIG. 7-04: OLAER FILLING DEVICE 13
FIG. 7-05: FLUSHING DEVICE 15
FIG. 7-06: FLUSHING DIAGRAM 15
FIG. 7-07: FLUSHING THE P AND T LINES TO THE APL 16
FIG. 7-08: FLUSHING THE P- AND T-PIPES TO THE STAND-BY ACCUMULATOR 17
FIG. 7-09: HIGH-PRESSURE HOSES 20
FIG. 7-10: PRE-ASSEMBLY BODY (VOMO) 22
FIG. 7-11: ERMETO-FITTING 25
FIG. 7-12: BLADDER OPERATION 28
FIG. 7-13: BLADDER: SECTIONAL DRAWING 29
TAB. 7-01: AMBIENT CONDITIONS FYRQUEL EHC 6

TAB. 7-02: FILTER CLASSES FOR HYDRAULIC SYSTEMS PER 100 ML TO SAE-ASTM
CLASSES 8
TAB. 7-03: VISCOSITY 15
TAB. 7-04: MATERIAL OF WELDING PIPES 26
APPENDIX REGISTER 7
1 CJC Fluid Treatment Unit

CJC Fluid Treatment Unit 15/25-15/25/S/MZ/HFD/AOJ/G/21/14560
Instructions for Use Document: BA-2GS61FDD0.0.02.0
2 Filling Device OLAER OSP 746

Tester and Pressurizer VGU

E07_104748-51
Instructions for Use
CJC Fluid Treatment Unit
15/25-15/25/S/MZ/HFDSO/AOJ/G/21/14560
Document : BA2GS61FDD0.0.03.0
Date of Modification : November 2007
State of Modification : A
Pages: 23
Intended Purpose : Chemical treatment of the gov-

ernor fluid (phosphate ester
based) for the prevention of
acidification with serial fine
filtration
General Drawing No. : KH1012250707220
Diagram : S2 AA 144 40
Serial Number :
Date of Fabrication :
Special Accessories : Pressure switch
1
Contents
1. Introduction 3
2. Intended Purpose 3
3. General Drawing 4
4. Technical Data and Wiring Diagram 11

4.1 Technical Data 11
4.2 Flow Diagram 12
4.3 Wiring Diagram 13
5. Safety Instructions 14
5.1 Due Application 14
5.1.1 Governor Fluids 14
5.1.2 Health 14
5.2 Safety at Work 14
6. Location Requirements 14
7. Commissioning and Operation 15
8. Putting out of Operation 16
9. Maintenance and Supervision 16

9.1 Maintenance 16
9.1.1 Maintenance of the CJC Fluid Treatment Unit 16
9.1.2 Exchange of the CJC Fluid treatment Cartridge 16
Exchange of the CJC Aluoxid Cartridge 16
9.1.3 Disposal 17
9.2 Supervision 17
9.2.1 Governor Fluid 17
9.2.2 Manometer 17
10. Function 18
11. Malfunctions, Possible Reasons, Trouble-Shooting 19

11.1 Table Trouble-Shooting 19
11.2 Exchange of Pump unit 21
12. Spare Parts 21
13. Warranty 21
2
1. Introduction
To ensure trouble-free, reliable, and - consequently - cost-effective operation, governor fluids

will constantly have to be in unobjectionable condition.
Constant care of the governor fluids is, therefore, indispensable.
CJC bypass fluid treatment units are high-class, compact units for the prevention of acidifica-
tion and fluid care, applied for governor fluids.
To protect your health and our environment, the latest EC directives have been strictly ap-
plied.
2. Intended Purpose
The CJC fluid treatment unit will have to be utilized solely for the intended purpose, which
has been clearly determined at the time of acknowledgement of order at the latest.
Any differing utilization is expressly inadmissible.
With your CJC fluid treatment unit, you may, consequently, filter only the governor fluids
listed on the cover of the present Instructions for Use. Any other utilization is inadmissible.
The CJC fluid treatment unit has been designed for continuous operation.
3
3. General Drawing
4
5
6
7
8
9
4. Technical Data and Wiring Diagram
4.1 Technical Data
The CJC fluid treatment unit will be delivered in completely assembled condition and ready-
for-connection, including Instructions for Use, but exclusive of governor fluid.
Your CJC fluid treatment unit will bear the CE mark.
Pump unit: Type MZ 0,35-0,12 BS 59,5

Pressure relief valve preset to 2.2 bar
Capacity: Q = 0,35 l/min at 1.390 rpm and 50 Hz

maximum admissible low pressure 0.3 bar
maximum suction head 2 m
Noise level: ≤ 73 dB/A at a distance of 1 m
Electric motor: Data on type plate motor (12.1)

Current connection acc. to wiring diagram in terminal cover (12.3)
Screwings: Cutting and locking screwings acc. to DIN 2353
Suction pipe (A) : AD 12

Filter outlet (B) : AD 12
Hose nozzle (14.2)
for drain cock (14) : Dia 12
Sealing material: Viton
Paint coating: RAL 5007
Net weight: approx. 67 kg
Operating weight: approx. 77 kg
10
4.2 Flow Diagram S2 AA 144 40
for CJC Fluid Treatment Unit 15/25-15/25/S/MZ/HFDSO/AOJ/G/21/14560
Diagram Offline Filtration
11
4.3 Wiring Diagram
AC 230 V: 3 x 230/400/440 V, 50 /60 Hz:
12
5. Safety Instructions
5.1 Intended Purpose
5.1.1 Governor fluids
There mustn’t be any governor fluid in the CJC fluid treatment unit during transport (delivery).
Leaking fluid will have to be immediately removed by means of absorbing material. The ab-
sorbing and cleaning materials soaked with governor fluid will have to be stored in labelled
containers and disposed of in compliance with official regulations.
5.1.2 Health
Cleaning rags and the like, soaked with governor fluid, must not be carried along in the cloth-
ing. Clothing that has been bespattered will have to be removed. Those parts of the skin that
have been in contact with governor fluid will have to be washed with water and soap. If there
is danger of spattering, the eyes will have to be protected with eye preservers.
If your eyes have been in contact with the governor fluid, immediately rinse them with running
water for 15 minutes, the eyelids wide open. Then see a doctor.
Protect your hands with protective gloves or with skin protection cream.
Do not eat, drink, or smoke during work with governor fluids.
As for the handling of governor fluids, we refer to the safety specifications acc. to
93/112/EG of the mineral oil industry.
5.2. Safety at Work
In case of fire, foam, powder, carbonic acid, sand or soil will be suited for extinguishing.
According to the directives of § 13 of the Ordinance on Workplaces, two hand fire extinguish-
ers size IV, P 12, must be available in the filter room.
To ensure safe operation of the CJC fluid treatment unit, the Client will have to prepare oper-
ating instructions based on the present Instructions for Use, indicating restrictions of applica-
tion and safety measures to be taken in case of malfunctions.
The operating instructions will have to be posted in a suitable place. They will have to be ob-
served by all employees.
6. Location Requirements
For installation of the CJC fluid treatment unit on the floor the unit has two squared tubes
(20.2) with one mounting hole 9 mm each.
If the CJC fluid treatment unit is installed near a fire source, the fire point of the governor fluid
applied will have to be taken account of (please refer to the safety specifications acc. to
93/112/EG of the mineral oil industry).
13
7. Commissioning and Operation
Please remove all packing material from the CJC fluid treatment unit and dispose of it ac-
cording to type.
Assembly, operation, maintenance, and disassembly of the CJC fluid treatment unit may be
carried out solely skilled staff. They will have to use suitable tools.
When putting the fluid treatmen unit into operation, the respective regulations regarding sub-
stances endangering a body of water have to be considered.
If your CJC fluid treatment unit is part of a hydraulic system, it may only be operated offline
the fluid circuit. For this purpose, the system tank the CJC fluid treatment unit is connected to
will have to be depressurized. The CJC fluid treatment unit has been designed for an operat-
ing pressure of 2.2 bar.
Mechanical connection:
The CJC fluid treatment unit will have to be connected to the suction side (A) and to the filter
outlet (B) by means of an oil-resistant hydraulic tube or by pipes according to DIN 2391.
Distortions owing to improper screwing will have to be avoided. In case of pipes, those of the
L series acc. to DIN 2391 will have to be utilized.
Connecting dimensions may be taken from Item 4 ‘Technical Data and Wiring Diagram’.
The connecting dimension of the return line (to be taken from Item 4 ‘Technical Data and Wir-
ing Diagram’ as well) must not be reduced.
The suction line will have to reach down below the fluid level of the system tank, so as to
avoid that air be sucked in. It should be connected as near as possible to the bottom of the
tank so as to be able to catch the sump. The return line should be placed in the tank as far as
possible from the suction line so as to avoid short-circuit filtration.
Electrical connection:
If your CJC fluid treatment unit has been delivered including electrical equipment, cabling to
the protection switch (24) will have to be done by an authorized electrician.
Correct mains voltage and sense of rotation of the motor (12) of the gear pump (11) will have
to be paid attention to (i.e. looking clockwise upon the fan acc. to the arrow on the motor indi-
cating the sense of rotation).
If the motor runs against the sense of rotation for a prolonged period, the pump will be dam-
aged.
The rotary field of the mains supply will have to correspond with the rotary field of the motor
(12) of the gear pump (11).
Connected loads and type of electrical connection are indicated on the type plate (12.1) of
the motor.
Providing the system tank has only a small capacity, the CJC fluid treatment unit will have to
be topped up from a separate tank with the governor fluid of the same variety by means of
the self-priming gear pump (11), so that there will remain sufficient governor fluid in the sys-
tem tank. The quantity of governor fluid required for topping up is indicated on the type plates
(20.1) of the filter housings (2). For this purpose, the motor (12) of the gear pump (11) will
have to be switched on by operating the protection switch (24). To allow filling of the CJC
fluid treatment unit with governor fluid, the filter housings (2) must be deaerated.
14
Deaeration will be done by turning the knurled screw (10.1) at the shut-off and air-vent valve
(10), or by turning the vent screw (8) counterclockwise by means of a wrench size 13.
As soon as governor fluid flows out of the shut-off and air-vent valve (10) or from the vent
screw (8), the knurled screw (10.1), or the vent screw (8) has to be shut by turning it clock-
wise.
If the manometer (9) has to be exchanged, it can be shut-off by turning the hand wheel (10.2)
at the shut-off and air-vent valve (10) clockwise. For this purpose, the CJC fluid treatment
unit will not have to be put out of operation.
Any governor fluid flown out during deaeration will have to be mopped up by means of suit-
able absorbing material. To prevent unintentional exit of governor fluid, the service staff will
have to be present at the CJC fluid treatment unit during the entire deaeration procedure.
As soon as the CJC fluid treatment unit has been filled with governor fluid, it will be put out of
operation for a short time by switching off the motor (12) of the gear pump (11) at the protec-
tion switch (24). Then the suction line (A) will be connected to the system tank - as described
above - and the motor (12) of the gear pump (11) will be re-started.
8. Putting out of Operation
The motor (12) of the gear pump (11) is switched off by operating the protection switch (24).
Solely an authorized electrician is permitted to disconnect the motor (12).
9. Maintenance and Supervision

9.1 Maintenance
The CJC fluid treatment unit does not require any special maintenance.
The sight glass of the manometer (9) will have to be kept clean to ensure readability.
9.1.1 Maintenance of the CJC Fluid Treatment Unit
The gear pump is self-lubricating owing to the governor fluid applied. Therefore, the CJC fluid
treatment unit is almost maintenance-free.
During operation venting (at 8 or 10) of the CJC fluid treatment unit has to be repeated as
required.
9.1.2 Exchange of the CJC Finefilter Cartridge and Aluoxid Cartridge
For exchange of the CJC finefilter cartridge and aluoxid cartride (4), the motor (12) of the
gear pump (11) has to be switched off by operating the protection switch (24).
You will have to wait until the pressure in the filter housings (2) has fallen towards 0 bar.
Discharge of the filter housings (2) will be done by opening the drain cocks (14) at the hand
lever (14.3) acc. to the position ‘ON/OFF’ counterclockwise by a quarter turn (against stop).
Stick a hose (Viton) upon the hose nozzle (14.2). The hose must end in a sufficiently dimen-
sioned collecting tank for governor fluid.
The connecting dimension of the hose with respect to the drain cock (14) may be taken from
the Technical Data.
15
The drain cocks (14) may not be used for sample taking for analysing purposes, as the gov-
ernor fluid to be encountered in this zone is contaminated.
As to the handling of governor fluids we refer to Item 5.1.1 ‘Governor fluids’.
Simultaneously, the knurled screw (10.1) at the shut-off and air-vent valve (10), or the vent
screw (8) will have to be opened with a wrench size 13 to aerate the filter housings (2).
The CJC fluid treatment unit is not empty as long as any governor fluid flows out of the open
drain cocks (14). We recommend to shut the drain cocks (14) immediately after the discharge
procedure so as not to forget it later.
Afterwards, the clamps (1.2) at the safety nut M8 (1.2.2) acc. to 985 of the hexagon screw
M8 x 80 (1.2.1) acc. to DIN 558 will have to be unscrewed by turning it counterclockwise by
means of a wrench size 13.
Then the filter domes (1) may be removed and the tightening nut (7) with the compression
spring (6) and the spring sleeve (5) have to be unscrewed manually by turning it counter-
clockwise.
The contaminated CJC finefilter cartridge and the exhausted CJC aluoxid cartridge (4) may
be lifted out. Previously, please allow the CJC finefilter cartridge and the CJC aluoxid car-
tridge (4) to drain off. It may then be put into the plastic bags of the spare CJC cartridges and
carried to your disposal container in the cardboard boxes intended for transportation.
We take this occasion to recommend a visual inspection of the base sealings (1.1) with re-
spect to their being intact and cleaning of the sealing surfaces on the bottom of the filter
housings (2).
The new CJC finefilter cartridge and the CJC aluoxid cartridge (4) will be carefully lowered
around the spindle (3). They should have tight contact with the sealing surface.
The aluoxid cartridge (4) must be fitted into the first filter housing (2) in connection
with the pump unit (11 + 12).
Manually tighten the tightening nut (7) with the compression spring (6) and the spring sleeve
(5) clockwise up to the stop.
After placing of the filter domes (1), tighten the clamps (1.2) by means of the hexagon screw
M8 x 80 (1.2.1) and safety nut M8 (1.2.2) using a wrench size 13 and turning clockwise.
9.1.3 Disposal of the CJC Finefilter Cartridge and CJC Aluoxid Cartridge
Used and contaminated CJC cartridges must be kept in appropriate and marked containers
and have to be disposed of according to the official regulations.
9.2 Supervision
9.2.1 Governor Fluid
Overacidification of the governor fluid can be verified only by carrying out analysis. In this
way the required replacement of the aluoxid cartridge (4) is established.
9.2.2 Manometer
The degree of contamination of the CJC finefilter cartridge (4) may be read from the ma-
nometer (9) on the filter dome (1).
16
The holding capacity of the CJC finefilter cartridge (4) for sediments is exploited to full advan-
tage as soon as the filter pressure has reached 2.2 bar, while the filter is at working tem-
perature.
As soon as the filter pressure has reached 2.2 bar, the CJC finefilter cartridge (4) will
have to be exchanged.
When the CJC finefilter cartridge (4) is contaminated, the pressure relief valve (opening pres-
sure 2.2 bar) will allow the governor fluid to flow back to the pump inlet.
In this case, the governor fluid is no longer filtered and, therefore, the CJC finefilter cartridge
(4) will have to be exchanged (cf. Item 9.1.2).
Please note that no filtration will be effected as soon as the filter pressure has reached
2.2 bar.
In case you should notice a filter pressure exceeding 2.2 bar yet when starting-up the CJC
fluid treatment unit, switch the CJC fluid treatment unit off and look up the possible reason
under Item 11.1 in the Table ‘Trouble-Shooting’.
10. Function
The motor (12) of the gear pump (11) will be switched on by operating the protection switch
(24). The contaminated governor fluid will be sucked from the system tank by the self-priming
gear pump (11), which will slowly and regularly pump it through the CJC aluoxid and CJC
finefilter cartridge (4), and that radially from the outside to the inside. Through the centre of
the filter housing the cleaned governor fluid will flow back into the system tank without pres-
sure.
To ensure maximum pump performance, low initial filter pressure, and optimum filtration, a
warm operating medium is required, which is available in most cases owing to the operating
temperatures given.
17
11. Malfunctions, Possible Reasons, Trouble-Shooting
11.1 Table Trouble-Shooting
Trouble Reason Remedy

Pump motor does not No mains voltage Check fuses
run
Differing mains voltage Exchange motor
Incorrect connections Effect correct connections acc.
to type plate and wiring diagram
in terminal cover
Wrong rotary field Reverse sense of direction by
re-connecting 2 external con-
ductors in the mains plug or in
the motor or by operating the
pole changing switch (if avail-
able)
Incorrect setting of protection Re-set protection switch acc. to
switch type plate
Pump does not take Leaky suction line Check suction line for leakages,
in re-tighten screwings, seal thread
Liquid level in the system Re-fill governor fluid
tank too low
Defective shaft sealing ring Exchange shaft sealing ring
Wrong sense of rotation of Reverse sense of rotation
the drive
Viscosity of the governor Use governor fluid with suitable
fluid too high viscosity
Initial filter pressure System tank placed on Place CJC finefilter unit on
too high higher level level of system tank
Cold governor fluid Warm up governor fluid
Kinked hose Straighten hose
Additional shut-off valve in Care for shut-off valve to be
re-circulation line open
Viscosity too high Use other type of CJC finefilter
cartridge
Delivery of the pump Pump shaft sheared off Repair by KARBERG & HEN-
is interrupted despite NEMANN
intact drive
Defective clutch Exchange clutch
Leaky suction line See above
Lack of governor fluid in the Re-fill governor fluid
system tank
Pump delivers with- Pressure relief valve does Clean pressure relief valve or
out or with little pres- not close owing to contamina- exchange valve spring
sure tion or defective valve spring
Considerable wear of the Repair by KARBERG & HEN-
pump NEMANN
Manometer does not Shut-off and air-vent valve Open shut-off and air-vent valve
indicate pressure closed
Defective manometer Exchange manometer
No CJC aluoxid-/finefilter Install CJC aluoxid-/ finefilter
18
cartridge cartridge
CJC fluid treatment unit not Re-fill CJC fluid treatment unit
filled
No tightening element with Fix tightening element
filter disc
Tightening element with fil- Increase tension of tightening
ter disc loose element up to stop
Leaky filter base seal- Clamp not sufficiently tight- Re-tighten clamp while filter is
ing ened depressurized
Defective O-ring Exchange O-ring

Air in filter Air in operating liquid taken Deaerate by means of Item 8 or
in 9
19
11.2 Exchange of the Pump Unit
If the pump unit (11 + 12) should have to be exchanged owing to a failure, at first the CJC
fluid treatment unit has to be discharged (as fully described under 9.1.2.).
Simultaneously, the motor (12) will have to be disconnected by an authorized electrician.

The CJC fluid treatment unit is not empty as long as any governor fluid flows out of the open
drain cocks (14).
The pump unit (11 + 12) then can be dismantled.
Then, the 4 hexagon nuts M6 (11.2) acc. to DIN 555 of the 4 stud bolts M6 x 20 (11.4) acc.
to DIN 938 will have to be unscrewed by means of a wrench size 10 to be turned counter-
clockwise. The 4 pertaining washers 6,4 (11.3) acc. to DIN 125 will have to be removed.
Then the pump unit (11 + 12) may be lifted forward. Preserve the nuts (11.2), the washers
(11.3) and the O-ring (11.1) for re-use.
Mounting of the pump unit will be carried out in reverse order.

As to return to service of the CJC fluid treatment unit, we refer to the detailed description un-
der Item 7. ‘Commissioning and Operation’.
As far as leakages are concerned that might occur during disassembly of the pump unit,
please refer to Item 5.1.1 ‘Governor fluids’.
12. Spare Parts

An order form for spare parts is attached. We shall be pleased to give you more detailed in-
formation upon request.
13. Warranty
For warranty refer to our sales terms and conditions of delivery as valid at the date of the
contract.
20
21
22
23
Accumulator Accessories
Tester and Pressurizer VGU
OLAER (Schweiz) AG
Bonnstrasse 3, CH – 3186 Düdingen
Tel. 026 492 70 00, Fax 026 492 70 70
E-mail: info@olaer.ch www.olaer.ch
Description OSP 746

The VGU tester and pressurizer is used for the charging of bladder, Move the manometer into a convenient position for
piston and membrane accumulators with nitrogen, and for testing or reading and tighten spigot nut (no. 5) with hand.
changing the pre-charge pressure. - Check that the bleed valve is closed (turn star knob
The instrument is suitable for all OLAER accumulatos with no. 20 clockwise).
5
/8 " and 7/8 " flap valves, Schrader valves or screw plugs.
It is screwed onto the gas valve of the hydropneumatic
accumulator and connected with the charging hose to a standard Accumulator with screw valve:
nitrogen cylinder . If only the pre-charge pressure needs to be che- - Turn star knob (no. 6) anti-clockwise till stop.
cked, the connection of the charging hose is not necessary. - Remove plastic cover of screw valve.
- Loosen screw valve with Allen screw width A/F 6.
Each unit comprises of: - Attach pressurizer without adapter to the screw valve. Move
- Tester and pressurizer with manometer, return valve on the the manometer into a convenient position for reading and
charging hose connection, built-in release valve, valve tighten the spigot nut (no. 5) by hand.
spindle for opening the gas valve or screw plug - Check that the bleed valve is closed (turn star knob
- Charging hose, lenght 2,5 m no. 20 clockwise).
- Connections for the accumulator:
® 7/8" - 14 UNF CHECKING THE PRE-CHARGE PRESSURE
® 5/8" - 18 UNF - Turn star knob (no.6) clockwise respectively anti-clockwise.
® 0,305" - 32 NFT The gas valve or Allen screw opens and pre-charge
® M28 x 1,5 pressure will register on the manometer.
- Platic protective case
REDUCING THE PRE-CHARGE PRESSURE
- Turn star knob (no.20) of the bleed valve slowly
anti-clockwise to exhaust the pre-charge pressure.
Maximum permitted operating pressure: depending on manometer,
max. 400 bar! Tighten Allen screw on membrane accumulator
with 20 Nm torque. PRESSURIZING / RAISING THE PRE-CHARGE PRESSURE
- Attach charging hose to return valve (no.7) and to
Type-code nitrogen flask.
- Open the stop valve on the nitrogen cylinder carefully.
Let the nitrogen flow slowly in the accumulator, till the
VG U - 250 - TS 3
desired pre-charge pressure is reached.
Type Charging hose - Close the stop valve on the nitrogen cylinder. After 5-10
Tester and Pressurizer TS 3: for CH, D, N, minutes (temperature compensation), check the pre-charge
S, A, FL, NL, pressure again and correct, if necessary.
Manometer DK, GUS
6, 10, 25, 60, 100, Connector
250, 400 , 600 bar W 24,32 x 1,814
400 bar
(for other countries see
part no. 40 on the rear page) For pre-charge pressures higher than the existing nitrogen
cylinder pressure the nitrogen charging unit SLG 1 (up to 400
For pre-charge pressures > 400 bar up to max. 600 bar the charging bar) can be used - see data sheet OSP 762.
hose TS 7 (700 bar) with the special adapter for the accumulator
connection of 7/8“ - 14 UNF (600 bar) must be used.
REMOVING
- Turn star knob (no.6) back.
Handling and precharging procedure - Turn star knob (no.20) anti-clockwise to exhaust the
PREPARATION pressurizer and charging hose.
- Before any pre-charge checks and/or nitrogen - Remove the pressurizer.
pressurizing, the hydraulic fluid of the hydropneumatic - Tighten screw valve with Allen screw width A/F 6.
accumulator must be discharged. - Test the gas valve for leaks using a leak detection spray.
- Replace the protective and/or seating cap with hand.
Accumulator with gas valve: Caution:
- Turn star knob (no. 6) anti-clockwise till stop. - Never use oxygen to prefill the accumulator.
- Remove the protective and/or seating cap of the gas valve. - Where the nitrogen cylinder pressure is higher than the
- Attach pressurizer with adapter no. 25 or 30 permitted accumulator working pressure, a pressure-
(+ connector no. 36 for Schrader valves) to the gas valve. reducing valve must be used in between!
Manufacturers's tolerances not taken into account Right to make modification reserved
Spare parts list
for VGU Tester and Pressurizer
Part Qty Part Rec.

No. Spare
1 1 Valve body
2 1 Valve spindle
3 1 Bolts
4 1 Split ring
5 1 Spigot nut
6 1 Star knob
7 1 Return valve
8 1 O-Ring x
9 1 Flat seal x
10 Hexagon nut
11 1 Retaining ring
12 1 Compression spring
13 1 O-Ring x
14 1 O-Ring x
15 1 Retaining ring
16 1 Centre-grooved dowel pin
17 1 Name plate
18 1 Connect. for manom. G 1⁄4"
19 1 Copper seal x
20 1 Star knob
21 1 Sealing gland
22 1 Valve spindle
23 1 Valve ball
24 1 Knurled cap
25 1 Adapter SAE 7/8" - 14 UNF compl.
26 1 Retaining ring
27 1 Adapter SAE 7/8" - 14 UNF
28 1 Valve spindle
29 1 O-Ring x
30 1 Adapter 5/8" - 18 UNF compl.
31 1 Retaining ring
32 1 Adapter 5/8" - 18 UNF
33 1 Valve spindle
34 1 O-Ring x
35 1 Flat seal x
36 1 Connect 0,305" - 32 NFT
37 1 Gasket assembly (complet set) x
38 1 Charging hose
40 1 Connectors for foreign nitrogen flasks
40b GB / AUS R 5/8" male
40c USA 24,51 x 1/14" male
40d Italy 21,7 x 1/14" male
40e Japan 22 x 1/14" female
40f Japan W 23 x 1/14" male Order example:

40g Brazil R 1/2" female
Gasket assembly Part No. 37 for VGU
40h F, B, E 21,7 x 1/14" female
40i China M 22 x 1,5 female
40k China 5
/8" female
40l Malaysia G 7/8" male
40m Trinidad 7
/8" - 14 UNF male
40n Bulgaria 3
/4" female
40o Philippines W 23 x 1/14" male
OSP 746-e - 1.2.2006 io

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DOCUMENT COVER SHEET

A 05-Dec-12 1st Issue

OPERATING & MAINTENANCE MANUAL

Supplied by: CCI AG, Switzerland

Order No.: S.O. 104748 P.O. 202787

Record Copy: 6560

CCI AG • Itaslenstrasse 9 • CH-8362 Balterswil • Switzerland

Das Urheberrecht an diesem Buch verbleibt bei CCI AG

Manual: Raigarh 6560

Register 2: Erection Instructions

Register 3: Description of Main Components

Register 4: Electrical & Electro-hydraulic Equipment

Register 5: General Maintenance Instructions

Dismantling & Assembly

Register 7: Hydraulic Power Unit

Register 8: Electronic Equipment

Register 9: Diagrams, Data Sheets & Dimensional Drawings, Vendor Literature

Sectional Drawings, Top Assembly Drawings, Parts Lists, Ordering

Das Urheberrecht an diesem Buch verbleibt bei CCI AG

NOTES FOR THE USER 3

HEALTH AND SAFETY 5

08.2012 Final Issue

3 Ordering of Spare Parts

3 Site Health and Safety Instructions

3.1. Safety Labels and Notes

3.1.2. Warning Sign with Note

The valve must be depressurized, cooled down to room temperature and

3.1.4. Care or Notice Sign with Statement

Caution: Hydraulic fluid may escape!

In addition, check for notes and comments on coverage.

IMPORTANT NOTES ON THE INSTALLATION OF CCI AG / SULZER LOW PRESSURE

GENERAL INSTRUCTIONS CONCERNING INSTALLATION OF CCI AG / SULZER VALVES 7

STORAGE INSTRUCTIONS FOR CCI AG / SULZER VALVES AND SYSTEMS 9

UNPACKING INSTRUCTIONS FOR CONTROL & INSTRUMENTATION EQUIPMENT 11

RESISTANCE OF CCI AG / SULZER VALVES AGAINST CHEMICAL CLEANING 12

RECOMMENDATIONS FOR PICKLING OF HYDRAULIC PIPES 14

LIST OF FIGURES REGISTER 2 15

Fig. 2-01: Examples of Poor Layouts

Fig. 2-02: Examples of Good Layouts

Fig. 2-03: Bypass Outlet Pipe; Good and Poor

4 Forces and Torques Acting on Bypass Valves

5 Accessibility of Valves, Dismantling

6 Layout of Hydraulic System

7 Measures for Noise Reduction

Fig. 2-04: Noise Bridges Between Piping and Outer Shell

1 Transportation at Installation Site

3.1. Welding the Valve in Piping Lines

3.2. Welding the Spray Water Nozzles

1 CCI AG / SULZER Packing

2 Permissible Conditions for Transport and Storage

3 Storage Area Categories

4.3. Measuring Transformers and Electronic Equipment

4.4. Spare Parts

5 Transfer of Risk and Take-over

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

1 Inspection with Prior Chemical Cleaning

To prevent renewed contamination, erection should be carried out

Pickling is not required if:

FIG. 2-01: EXAMPLES OF POOR LAYOUTS 3

ELECTRO-HYDRAULIC ACTUATOR SYSTEM WITH PROPORTIONAL VALVE 2

ACTUATORS ASM AND GHZ CLASS 11

SINGLE ACTION CONTROL UNIT (SACU) 13

PV CONTROL UNITS 14