CONTENTS

General Information
Specification
On receipt of equipment
Equipment inspection
Equipment check list
Safety
Component parts of the Actuator
Actuator controls
Control bar advance/retract
Control bar clamp operation
Pre-linestopping preparation
Actuator hydraulic oil filling procedure
Plugging head sealing element installation
Table 1 - Torque values
Line stop housing
Plugging head assembly installation
Line stop selection
Line stop fitting selection
Sandwich valve installation
Obtaining measurements
Plugging head setting distance
Installation
Actuator slinging and lifting
Installation of line stop equipment
Maintenance
Dismantle and re-assembly procedures

Issue 1

3
4
5
5
5
6
7
9
9
9
11
11
11
12
13
14
15
15
15
15
16
17
17
18
19
19

Page 1

Page 2

Issue 1

GENERAL INFORMATION
The procedures and instructions contained in this manual should be carefully read and understood
by all personnel concerned with operation and maintenance of this equipment. Using the correct
procedures for operation and maintenance will increase the life of the equipment.
Do not alter the actuator in any way, use only replacement parts manufactured or recommended by
IPSCO and, if in doubt, return the machine to the factory for maintenance.
Special attention should be paid to the warnings and cautions in the SAFETY section and elsewhere
in this manual. They are included to indicate possible dangers to personnel and equipment.
If any part of this manual is not fully understood or questions arise, please contact your nearest
International Piping Services Company.
The four sizes and part numbers of actuator covered by this manual are as follows:

6 in. Thru 12 in.

Series 1

14 in. Thru 20 in.

Series 2

22 in. Thru 34 in.

Series 3

36 in. Thru 48 in.

Series 4

Issue 1

Page 3

SPECIFICATION
Maximum actuator hydraulic power requirements:

Variable flow at 1000 psi (69 bar)

Maximum pipeline operating pressure:

1800 psi (124 bar)

Maximum end pressure test (Hydrostatic):

2700 psi (186 bar)

Operating temperature:
Control bar travel:

Hydraulic control valve:

Cartridge relief valves (see note below):
Actuator size ranges:

Note:

Page 4

-28.8C to +83C(-20F to +180F)

Series 1
Series 2
Series 3
Series 4

- 72 in.
- 102 in.
- 140 in.
- 140 in.

Mannesman/Rexroth
Webtec
6 in. Thru 12 in.
14 in. Thru 20 in.
22 in. Thru 34 in.
36 in. Thru 48 in.

The control valve manifold is fitted with cartridge relief valves set to 1015 psi ( 70
bar) for pressure relief due to thermal expansion. The pressure vents through a
hole in the end of the quick release coupling on the return line from the manifold.

Issue 1

ON RECEIPT OF EQUIPMENT
EQUIPMENT INSPECTION

Line stop Actuator

Protector/test end c/w 1 inch UNC Stud

and nut set (8 off)

Inspect equipment and report any

damaged or missing equipment to IPSCO
immediately (see equipment check list).

Lifting brackets c/w clamping bolts (4 off)

Head fixing screws c/w Nyloc nuts (2 off)

Inspect the actuator for damage or

leakages.

Hexagon wrench key.

The actuator is thoroughly checked before

leaving the factory, however, on receipt of delivery
the following checks must be made prior to
putting the equipment to use:

EQUIPMENT CHECK LIST

To prevent damage occurring

during transportation and
storage, ensure that the
actuator protector/test end is
installed and the valve guard is
in position.

Issue 1

Page 5

SAFETY
CORRECTLY FITTING PROTECTIVE CLOTHING IS RECOMMENDED
WHENEVER WORKING WITH MACHINERY. LOOSE OR BAGGY CLOTHING CAN
BE EXTREMELY DANGEROUS WHEN OPERATING OR SERVICING MACHINERY.
OTHER ITEMS WHICH SHOULD BE CONSIDERED ARE HARD HAT, GAUNTLET
GLOVES, SAFETY SHOES, GARMENTS TO COVER EXPOSED AREAS OF SKIN
AND BREATHING APPARATUS WHEN A TOXIC ATMOSPHERE EXISTS

DO NOT ATTEMPT AN OPERATION WHICH WOULD DEPART FROM THE

PROCEDURES DESCRIBED IN THIS MANUAL. TO DO SO COULD PRESENT A
HAZARDOUS SITUATION CAUSING INJURY TO PERSONNEL AND/OR DAMAGE
TO THE EQUIPMENT.

DO NOT ALTER THIS EQUIPMENT OR ANY OF ITS COMPONENT PARTS. USE

ONLY REPLACEMENT PARTS MANUFACTURED OR RECOMMENDED BY
IPSCO.

Page 6

Issue 1

COMPONENT PARTS OF THE ACTUATOR

Key
1.
2.
3.
4.
5.
6.
7.

Lifting point
Control bar
Directional control valve
Quick release couplings
Control bar clamp
Clamp spacer
Socket head cap screw

FIGURE 1
Issue 1

Page 7

Page 8

Issue 1

ACTUATOR CONTROLS
Control Bar Advance/Retract
(Refer to Figure 2)
The directional spool valve (1) is a three position
control valve with advance, neutral and retract.
To advance the control bar (4), push the handle
(2) on the directional spool valve (1) in the
indicated direction of the Advance Arrow as
shown on the valve label (3). To retract the control
bar (4), push the handle (2) in the indicated
direction of the Retract Arrow.
Note:

The direction of handle operation

corresponds with the direction of
control bar movement.

Control Bar Clamp Operation

(Refer to Figure 3)
To prevent control bar movement during the line
stop operation, a locking device is located at the
flange end of the actuator.

FIGURE 2

The locking device consists of three clamps (5).

The locking clamps (5) are operated by rotating
the three socket head cap screws (7) in the
spacers (6) with the hexagon wrench provided.

FIGURE 3
Issue 1

Page 9

Page 10

Issue 1

PRE-LINESTOPPING PREPARATION
Actuator Hydraulic Oil Filling
Procedure
(Refer to Figure 1)
To fill the actuator with oil proceed as follows:
During the filling procedure,
periodically check and top up
the power unit reservoir level.
Only top up the reservoir when
the actuator directional control
valve is in the neutral position.
Connect the two sizes of hose from the power
unit to the actuator via the non-interchangeable
quick release couplings (4).
Start the power unit and set the throttle to 1000
rpm.
Set the handle of the directional control valve (3)
to the Advance position, the actuator will begin
to fill behind the piston. Air from front of the piston
is purged through the return line to the power
unit.
Set the handle of the directional control valve (3)
to the Retract position to fill the opposite end of
the actuator. Air will be purged through the return
line to the power unit.
Repeat this procedure several times to ensure
that the actuator is full of oil and all air has been
purged.

Plugging Head Sealing Element Installation

FIGURE 4

When you install the nose

assembly (6), ensure that the
nose block (4) is uppermost as
shown.
Refit the nose assembly (6), ensure nose block
(4) is uppermost.
Clamp the element (3) using the cap screws 12
off (5) removed previously.
Tighten the cap screws (5) in sequence to the
prescribed torque, ( Refer to Table 1 and Figure
5).
Liberally coat the lip of the sealing element (3)
with grease for protection.

(Refer to Figure 4)
To install the sealing element (3) to the plugging
head (1) do as follows:
Remove the socket head cap screws 12 off (5)
retaining the nose assembly (6).
Remove the nose assembly (6) from the yoke
(2).
Install the element (3) on the face plate of the
yoke (2).
Issue 1

Page 11

PRE-LINESTOPPING PREPARATION

FIGURE 5

Table 1
Tightening Torque Values for Imperial Fasteners

Page 12

Bolt Size
(ins.)

Min. Yield Strength

(psi)

Bolt Tension
(lbs)

0.625
0.750
0.875
1.000
1.125
1.250
1.375
1.500
1.625
1.750
1.875
2.000
2.250
2.500
2.750
3.000
3.250
3.500
3.750
4.000
4.250
4.500

105000
105000
105000
105000
105000
105000
105000
105000
105000
105000
105000
105000
105000
105000
95000
95000
95000
95000
95000
95000
75000
75000

10305
15466
21525
28323
38902
49560
61530
74760
89250
105000
122325
140700
181125
226800
251750
302100
357675
418000
482600
551950
494250
556500

Torque
Required lbf ft (Nm)

146
258
415
620
953
1338
1816
2393
3081
3888
4836
5914
8521
11806
14367
18753
23995
30137
37212
45324
48062
51274

(198)
(350)
(563)
(841)
(1292)
(1814)
(2462)
(3245)
(4177)
(5217)
(6557)
(8018)
(11553)
(16007)
(19479)
(25425)
(32532)
(40860)
(50452)
(61450)
(58383)
(69517)

Issue 1

PRE-LINESTOPPING PREPARATION
Line Stop Housing
(Refer to Figure 6)
Line stop housings are used together with IPSCO
plugging heads and actuators. The housings
come complete with equalization and purge connections. They are constructed to ensure
concentricity and parallel faces and are available
with all standard flanges.
To install the actuator to the line stop housing
proceed as follows:
Support the actuator (1) in the horizontal position
and remove the protector/test end from the
actuator (1).
Select the correct line stop housing.
Ensure that the O ring seal (4) is in the machined
groove of the housing (5) top plate.
With the actuator control valve (2) in line with the
housings 2 inch equalization connection (6), bolt
the housing (5) to the actuator (1) with the (8 off)
cap screws (3) provided.
Tighten the cap screws (3) in sequence (Refer
to Figure 5) to a torque of 750 lbf ft.
Ensure that the actuator control valve (2) is in
line with the 2 inch equalization connection (6)
on the housing (5).

FIGURE 6

Issue 1

Page 13

PRE-LINESTOPPING PREPARATION
Plugging Head Assembly
Installation
(Refer to Figure 7)
SUPPORT THE WEIGHT OF
THE PLUGGING HEAD (6)
WHEN IT IS PROTRUDING
FROM THE HOUSING (3).
RETRACT THE SEALING
ELEMENT (7) CAREFULLY TO
PREVENT THE LIP BEING
PULLED INSIDE OUT. DO NOT
LEAVE THE ELEMENT (7) IN
THE HOUSING (3) OVER LONG
PERIODS AS THE EDGES WILL
FLATTEN AND REDUCE THE
EFFECTIVENESS OF THE
SEAL.
To install the plugging head assembly proceed
as follows:
With hydraulic power connected, advance the
control bar (2) beyond the flange face of the
housing (3).
Select the correct line stop plugging head.
Ensure that the 2 inch equalization connection
(4) on the housing (3) and the plugging head (6)
are in line.
Push the plugging head (6) on to the control bar
(2) and bolt together with the two cap head
screws and nuts (5) provided.
Use the actuator control valve to retract the
plugging head (6) into the housing (3) until zero
registers through the observation hole (1).
Tighten the control bar clamps (Refer to Control
bar clamp and Figure 3).

FIGURE 7

Page 14

Issue 1

PRE-LINESTOPPING PREPARATION
Line stop Valve Selection
Only IPSCO sandwich valves should be used
during line stopping operations. For more
information on sandwich valves refer to the
sandwich valve manual.

Line stop Fitting Selection

Only IPSCO full encirclement type fittings are
recommended for line stop operations..
It is imperative that all fittings are manufactured
and attached to the pipeline accurately.
Alignment of the fitting to the pipeline is crucial
to the success of the line stop operation.

Sandwich Valve Installation

Refer to your sandwich valve manual and tapping
machine operation and maintenance manual for
installation of the sandwich valve.
On completion of the hot tapping procedure and
the onset of the line stop equipment installation,
the sandwich valve will already be in place and
in the closed position.

Obtaining Measurements
(Refer to Figure 8)
The actuator control bar (1) is calibrated with
numbers at 1 inch increments over the range to
indicate the distance it has travelled. The number
that is visible through the observation hole (2) is
the actual distance travelled in inches.

FIGURE 8

Issue 1

Page 15

PRE-LINESTOPPING PREPARATION
Plugging Head Setting Distance
(Refer to Figure 9)
TAKE MEASUREMENTS AND
CALCULATE THE SETTING
DISTANCE CAREFULLY AS
THESE ENSURE THAT THE
HEEL (5) OF THE PLUGGING
HEAD (3) IS IN CONTACT WITH
THE PIPELINE BOTTOM (7).
To find the plugging head setting distance
proceed as follows:
Ensure that the plugging head (3) is fully retracted
and that the figure zero is visible through the
observation hole (2) of the actuator (1).
Measure the distance from the base of the
plugging head heel (5) to the flange face of the
line stop housing (4). Record as distance A.
Note:

Distance B can be taken before the

hot tapping procedure or the same
measurement used in the hot
tapping lower-in distance
calculation can be used. Refer to
your tapping machine operation
and maintenance manual for
details.

Measure from the top of the sandwich valve (6),

including the gasket height, to the top of the
pipeline (7). Record as distance B.
Identify the outside diameter of the pipe (7) and
subtract one pipe wall thickness. Record as
distance C.
Setting distance = A+B+C.

FIGURE 9

Page 16

Issue 1

INSTALLATION
Actuator slinging and lifting
(Refer to Figure 10)
When slinging and lifting the actuator use only
the lifting brackets provided.
When lifting the fully rigged actuator into the
vertical position, two independent lifting devices
are strongly recommended.

FIGURE 10

Issue 1

Page 17

INSTALLATION
Installation of Line stop Equipment
Key to Figure 11
1.
Actuator
2.
Purge valve/gauge line
3.
Plugging head
4.
Housing
5.
Equalization connection
6.
Plugging head nose wheels
7.
Sandwich valve
8.
Gate valve
9.
Line stop fitting
(Refer to Figure 11)
Ensure that the control bar clamps are tight.
Sling and lift the rigged actuator into position to
interface with the sandwich valve (7).
Ensure that the gasket is in position and the
plugging head nose wheels (6) do not touch the
closed sandwich gate valve (8).
Carefully lower the assembly.
Ensure the line stop housing equalization
connection (5) and the plugging head articulation
is towards the section of pipeline to be isolated.
Tighten the sandwich valve stud nuts in sequence
to the prescribed torque (Refer to Figure 5 and
Table 1).

FIGURE 11

Connect the equalization, purge valve, drain and

pressure gauge facilities to the housing.
Connect the two sizes of hose from the power
unit to the actuator via the non-interchangeable
quick release couplings.
Start the power unit.
The Installation of the line stop equipment is
now complete and the line stop procedure can
now be performed (Refer to the Hot Tap and
Line Stop Manual).

Page 18

Issue 1

MAINTENANCE
The actuator O ring seals should be replaced
during any dismantling and the annual overhaul
of the actuator.
The scraper seal, pressure seals and piston seals
should be replaced when signs of any wear or
damage are found.
The maintenance and regular replacement of the
pressure seals is very important. They provide a
barrier between cylinder pressure and the
pressurized pipeline environment.
Before leaving the factory, the front pressure seal
is tested to 2700 psi using the protector/test end.
Before each line stop operation, the actuator
should be pressure tested to 2700 psi for 30
minutes. If a pressure drop is detected, the front
pressure seal should be replaced.
The control bar end should be coated with light
oil before long periods of storage.

Dismantle and Re-Assembly

Procedures
(Refer to Figure 12)
Note:

Before the installation of a seal you

must ensure the seal seating area is
clean.

Dismantle Procedure
To dismantle the actuator, proceed as follows:
Position the actuator in the horizontal position
with the two pressure plugs (18) face down.
Remove the eight stud and nut sets (10) and
remove the protector/test end (11).
Remove the two pressure plugs (18) and drain
the fluid from the cylinder body (6) into a suitable
container.
Remove the twelve cap screws (2) and the end
flange assembly complete with anti-rotation bar
(3).

Issue 1

Remove and discard the O-ring seal (1).

Remove the eight cap screws (15) from the seal
housing (14).
Slide the seal housing (14) and clamp housing
(16) complete with control bar clamps (8) from
the control bar (5).
Remove and discard the O-ring seal (17) on
clamp housing (16).
Remove the three cap screws (21) and three
clamp spacers (20) from the clamp housing (16).
Remove the three control bar clamps (8) and pin
(19) from the clamp housing (16).
Support the control bar when it
is removed from the cylinder.
Use the two holes in the end of control bar (5) to
pull the control bar piston free from the cylinder
body (6).
Re-Assembly Procedure
To re-assemble the actuator proceed as follows:
Examine the two piston seals (22) for wear or
damage. To replace worn or damaged piston
seals (22), do as follows:
Remove the six cap screws (24), bar stop (4)
and the anti-rotation plate (23). Replace the two
piston seals (22) and refit the anti-rotation plate
(23) and bar stop (4) to the control bar (5). Clamp
the assembly with the six cap screws (24) in
sequence to the prescribed torque (Refer to
Table 1 and Figure 5).
Support the control bar (5) and guide the leading
piston seal into the cylinder (6) to prevent
damage. Refit the control bar (5) to the cylinder
(6).
Refit the pin (19) and three bar clamps (8) to
clamp housing (16).
Refit the three clamp spacers (20) and three cap
screws (21) to clamp housing (16).

Page 19

MAINTENANCE

FIGURE 12
Page 20

Issue 1

MAINTENANCE
Note:

If the pressure seal (13) is to be

replaced in the clamp housing (16),
you must ensure the pressure side
of the seal (13) is assembled
against the cylinder internal
pressure.

Examine the pressure seal (13) in clamp housing

(16) for wear or damage. If wear or damage is
found, replace the pressure seal (13). Ensure the
pressure side of the seal (13) is against the
cylinder internal pressure.

Slide the seal housing (14) onto the control bar

(5). Clamp the seal housing (14) with the eight
cap screws (15) in sequence (Refer to Figure
5) and torque tighten to 120 lbf ft.
Install new O-ring (1) to the end flange (3).
Slide the anti-rotation bar through the centre of
the control bar (5) and align end flange (3) to the
main cylinder body (6). Ensure the lifting eye is
in line with the directional control valve (7).

Install new O-ring (17) to the clamp housing (16).

Refit the twelve cap screws (2) in sequence

(Refer to Figure 5) and torque tighten to 80 lbf
ft.

Slide the clamp housing (16) onto the control bar

(5) and into the main cylinder body (6). Align the
observation hole in main cylinder body (6) with
the hole in the clamp housing (16).

Refit the two pressure plugs (18) to the cylinder

main body (6).

Note:

If the pressure seal (13) is to be

replaced in the seal housing (14),
you must ensure the pressure side
of the seal (13) is assembled facing
the external product pressure.

Examine the scraper seal (12) and pressure seal

(13) in the seal housing (14) for wear or damage.
If wear or damage is found, replace the scraper
seal (12) and pressure seal (13). Ensure the
pressure side of the seal (13) is facing the
external product pressure.

Issue 1

Replenish the actuator with hydraulic oil and

check operation as detailed previously (Refer to
Actuator hydraulic oil filling procedure).
Fully retract the control bar (5).
Refit the protector/test end (11) complete with
O-ring (9) and clamp with the eight stud and nut
sets (10).

Page 21

Page 22

Issue 1

IPSCO (UK) Ltd.

Sunningdale House
Sunningdale Road
South Park Industrial Estate
Scunthorpe
United Kingdom
DN17 2TY
Tel. 00 44 1724 849904
Fax. 00 44 1724 861033
EMAIL: info.Ipsco@flowserve.com
HOME PAGE: www.ipscouk.com

Issue 1
14 February 2003