BIFFI OLGAS, Installation, Operation And Maintenance Manual

Page 1: ...ic Actuators Copyright Biffi The information in this document is subject to change without notice Updated data sheets can be obtained from our website www biffi it or from your nearest Biffi Center Biffi Italia s r l Strada Biffi 165 29017 Fiorenzuola d Arda PC Italy PH 39 0523 944 411 biffi_italia biffi it ...

Page 2: ...ared Checked Approved 5 December 2020 Migration to new template 4 April 2020 Updated DATAPLATE Ermanni Orefici Vigliano 3 April 2018 Updated applicable regulation chapter 1 1 1 Ermanni Orefici Vigliano 2 July 2012 General update Ermanni Stoto Vigliano 1 February 2010 General update Ermanni Stoto Vigliano 0 May 1999 Document release Lazzarini Aliani Ziveri ...

Page 3: ...on Actuator Receipt 4 2 2 Actuator Handling 4 2 3 Storage 7 2 4 Actuator Assembly on the Valve 8 2 4 1 Types of Assembly 8 2 4 2 Assembly Procedure 13 2 5 Hydraulic Connections 14 2 6 Electrical Connections If Any 14 2 7 Commissioning 15 Section 3 Operation and Use 3 1 Operation Description 16 3 2 Residual Risks 17 3 3 Operations 17 3 3 1 Emergency Manual Operation 17 3 3 2 Remote Control Operatio...

Page 4: ...eck and Restore Oil Level in the Hydraulic Manual Handpump 29 5 2 Extraordinary Maintenance 31 5 2 1 Replacement of Cylinder Seals 32 5 3 Lubrication of Mechanism 35 5 4 Dismantling and Demolition 36 Section 6 Troubleshooting 6 1 Failure or Breakdown Research 37 Section 7 Layouts 7 1 Spare Parts Order 38 7 2 Parts List for Maintenance and Replacing Procedure 39 Section 8 Date Report for Maintenanc...

Page 5: ...y of machinery General principles for design Risk assessment and risk reduction 2006 42 EC Machine directive 2014 68 EU Directive for pressure PED equipment 2014 35 EU Directive for low voltage equipment 2014 30 EU Directive for the electromagnetic compatibility 2014 34 EU Directive and safety instructions for use in hazardous area NOTICE Biffi Italia s r l pays the highest attention to collecting...

Page 6: ... conditions are specified in the documentation forwarded together with the product This warranty does not cover special products or components not warranted by subcontractors or materials that were used or installed improperly or were modified or repaired by unauthorized staff In the event that a fault condition be caused by improper installation maintenance or use or by irregular working conditio...

Page 7: ...e cover of the scotch yoke mechanism is arranged for the assembly of the required accessories positioner signalling limit switches position transducer etc by means of proper matching units The above mentioned accessories are operated by the actuator drive sleeve The housing of the scotch yoke mechanism has a flange with threaded holes to fix the actuator to the valve either directly or if required...

Page 8: ...assembled with the valve its settings have already been made at the factory If the actuator is delivered separately from the valve it is necessary to check and if required to adjust the settings of the mechanical stops Section 3 4 and of micro switches if any Section 3 5 2 2 Actuator Handling NOTICE The lifting and handling of the actuator must be done by qualified personnel and in accordance with...

Page 9: ...g equipment used and discard it if not in perfect working order Do not knot or twist the ropes so as not to reduce the lifting capacity or produce torsional effects on the load being lifted Use the utmost caution and remain at a safe distance from lifted actuator unless absolutely necessary do not stand or pass under suspended loads Pay attention in putting under tension the ropes to prevent the l...

Page 10: ...osition the tank of MHP to avoid leakage on oil level stick substitute these with a blind plug during the transport a specific warning label for transport in horizontal position is attached on the MHP body remove the blind plug and restore the dipstick before operate the actuator with MHP Biffi hydraulic manual handpump must be maintained with tank under the handpump to operate the actuator with M...

Page 11: ...the position of suction pipe and breather cap 2 3 Storage If the actuator needs storage before installation follow these steps Place it on a wood surface in order not to deteriorate the area of valve coupling Make sure that plastic plugs are present on the pneumatic and electrical connections if present Check that the cover of the control group and of the limit switch box if any are properly close...

Page 12: ...ediate flange when required This intermediate flange or spool piece can be supplied when the valve flange can not directly match the actuator flange in its standard configuration For the biggest actuator models the actuator flange can be machined in accordance with the valve flange dimensions The yoke has bored with keyways for coupling to the valve stem the dimensions of which are according to Bi...

Page 13: ...Ø d2 0 1 Ø d3 0 2 Ø d1 0 h 1 0 5 Ø d4 h 2 Ød5 0 2 0 1 K 0 4 0 W D10 0 9 Section 2 Installation Figure 8 Coupling dimensions Models 0 3 to 6 Drive sleeve N threaded holes PCD number and size according to ISO 5211 but the holes are on centerline instead of straddle the centerline Flow line Top view of the Scotch yoke mechanism actuator shown in closed position N 4 holes flange N 8 holes flange max D...

Page 14: ...e Manual MAN 608 Rev 5 Installation Ø d1 Ø d4 h 2 Ø d2 0 1 0 Ø d3 0 2 h 1 0 5 0 H max Ø d5 0 2 0 1 K 0 4 0 W D10 10 Section 2 Installation Dimensions in millimeters Actuator model Ø d1 Ø d2 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K Flow line Drive sleeve Figure 9 Coupling dimensions Models 14 to 42 N 12 holes flange N 16 holes flange max Table 2 SCN6201 Top view of the Scotch yoke mechanism actuator shown ...

Page 15: ...h 2 Ø d2 0 1 0 Ø d3 0 2 h 1 0 5 0 H max Ø d5 0 2 0 1 K 0 4 0 W D10 Dimensions in millimetersw Actuator model Ø d1 Ø d2 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K Drive sleeve N THREADED HOLES Flange sizing according to ISO Top view of the scotch yoke mechanism actuator shown in closed position Flow line Table 3 SCN6201 1 11 Section 2 Installation Figure 10 Coupling dimensions Models 50 and 60 max ...

Page 16: ...45 allows to position the keyway for the valve every 90 Consequently actuator can be mounted in 4 positions at 90 on top of the valve For biggest actuator models the bore of the yoke can be machined according to the dimensions of valve stem Flow line N 4 holes flange N 8 holes flange Drive sleeve Snap ring Housing Insert bush Insert bush Adaptor flange Drive sleeve Standard position 1 Position 2 P...

Page 17: ...operly clean and remove grease from valve coupling flange surfaces Connect if supplied separately the stem extension onto the valve stem and fasten it with the special fastening pins Lift the actuator using the special lifting points Section 2 2 Install the actuator so that valve stem inserts in the coupling area This coupling should be made without forcing Fasten the two parts with the threaded c...

Page 18: ... avoid possible damages to the unit or loss of performance The inside of the pipes used for the connections must be well cleaned before use wash them with suitable substances and blow through them with oil or nitrogen The ends of the tubes must be well debarred and cleaned Once the connections are completed operate the actuator and check that it functions correctly that the operation times meet th...

Page 19: ... 1 and on the documentation supplied Check the power voltage of electrical components complies with the one reported on the documentation supplied and with specific data plate placed on electrical components Check the absence of leakages in the cylinder and in hydraulic connections Check that paint is intact and in case renovate it according to the specification on order confirmation Carry out all...

Page 20: ... which valve stem is coupled The fluid contained in the other chamber is discharged through the return line In the second case cutting off or in case of lack of pressure to the cylinder and to the pilot of the fast discharge valve the opening of the latter is determined the fast discharge of motor fluid the quick extension of the spring and the consequent fast operation of the actuator The motor f...

Page 21: ...lied by a power pack for the normal actuator operation The emergency manual override mounted on the actuator consists of an hydraulic manual override and a hydraulic manual selector to choose the actuator Normal operation with oil supply from a power pack or the Emergency manual operation The compact hydraulic manual override consists of handpump to deliver oil from the tank to the actuator cylind...

Page 22: ...h the complete operation Check the correct operation of the actuator through the visual position indicator Open the stop valve 5 S to operate to fail safe position Note that the stop valve 5 S must be in open position to allow the operation with hydraulic supply see Section 7 2 Figure 31 sectional drawing for hydraulic control unit MHP 1 Scotch yoke mechanism 2 Hydraulic cylinder 3 Spring cartridg...

Page 23: ...r automatic operation or stay put in case of emergency conditions electric or hydraulic supply failure high temperature low or high pipeline pressure etc The control systems have where is possible a manifold design the components are connected by a flange to the manifold or assembled into the cavities machined into the manifold This allows to have a very compact unit to reduce the number of connec...

Page 24: ...a correct selection of schematics components materials and protection treatment The energy supply for the power pack operation can be electric direct current or alternate current and or pneumatic low pressure or high pressure Handpump manual override available on request for oil supply to the actuator in case of energy supply failure The power pack components can be supplied panel mounted or enclo...

Page 25: ...anical stops screwed at the end of spring cartridge and into the end flange of the pneumatic cylinder Figure 17 For the adjustment of the mechanical stop on the end flange of cylinder follow these steps Figure 18 Remove with the specific wrench c1 the plug t Insert a wrench for Allen keys c2 in the through hole until reaching the adjustment pin g Keep the protection cover blocked with the special ...

Page 26: ...peration and Use c2 c1 g c3 22 Section 3 Operation and Use Hydraulic Cylinder Size Wrench C1 mm Wrench C2 mm Wrench C3 mm Figure 18 Mechanical stop of the cylinder 075 22 10 36 100 22 10 36 135 22 10 36 175 22 14 46 200 27 14 46 235 27 17 65 280 27 17 65 300 36 17 110 Table 6 ...

Page 27: ...pped before reaching the end position unscrew the stop screw v by turning it anticlockwise until the valve reaches the correct position 3 If the stop screw is too hard to be operated reduce or remove the cylinder pressure in order to move the mechanism far from the screw Operate the setting screw and then pressurize again the cylinder to reach end position 4 If the actuator angular stroke is stopp...

Page 28: ... 17 100 8300 17 100 9600 17 100 9800 17 100 11000 17 100 15000 17 130 15600 17 130 December 2020 Installation Operation and Maintenance Manual MAN 608 Rev 5 Operation and Use 24 Section 3 Operation and Use To operate the adjustments refer to following Tables Spring container size Wrench C1 mm Wrench C2 mm Spring container size Wrench c1 mm Wrench c2 mm Table 7 Table 8 ...

Page 29: ...switch box model NOTICE For mounting interface dimension of the Limit Switch box on the cover of the actuator please refer to TN1163V for metric dimension or TN1163VU for imperial dimension NOTICE Operate only the micro switch corresponding to the direction of operation being carried out as clearly reported on the micro switch End of stroke microswitches should be operated before the stop of the s...

Page 30: ...range C 45 60 Mass kg 0 70 Hydraulic fluid mineral oils Recommended filtration 19 15 ISO 4466 25 µ obsolutes Seals in MFQ Fuoro silicone Figure 22 Adjustment of operating time by flow regulator valve OUT IN Torque 30 Nm Torque 5 Nm 3 6 Calibration of the Operation Time If Required The calibration of the operation time is made by Biffi Italia s r l according to customer requirements and to technica...

Page 31: ...Tests and Inspections 27 Section 4 Operational Tests and Inspections Section 4 Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade according to IEC 61508 the functionality of actuator must be checked with regular intervals of time as described in the Safety Manual ...

Page 32: ...he actuator operates the valve correctly and with the required operating times If the actuator operation is very infrequent carry out a few opening and closing operations with all the existing controls remote control local control emergency controls etc if this is allowed by the conditions of the plant Check there are no hydraulic or pneumatic leakages If necessary tighten the nuts of the pipe fit...

Page 33: ... add the oil proceeding as follow Remove the dipstick 1 from the tank cover 22 Unscrew the plug 27 and the washer 9 to drain all the oil If some dirt or and sludge is found in the oil drained from the tank before filling with new oil in the tank disassemble the oil tank tube by unscrewing the two cap nuts 2 and clean the internal surfaces of the tank If necessary substitute the gaskets 21 of the t...

Page 34: ...me AEROSHELL FLUID 41 Viscosity at 54 C 2300 cST Viscosity at 40 C 491 cST Viscosity at 40 C 14 1 cST Viscosity at 100 C 5 30 cST Viscosity index ISO 2909 200 Flash point 105 C Pour point 60 C Specific weight or equivalent 0 87 kg dm3 Low temperature conditions until 60 C Manufactured SYNTESIS Name SYNTRASS CS 500 Viscosity at 60 C 580 cST Viscosity at 30 C 39 cST Viscosity at 20 C 5 8 cST Viscosi...

Page 35: ...eference to the follow general sectional drawing and adopting the following procedures WARNING If the actuator can be operated it is essential to take it to fail safe position with the spring totally extended otherwise the actuator should be disassembled from the valve and follow these steps Remove the plug from the cover of the adjustment screw 23 Record the length between end flange and stop set...

Page 36: ...n rubber If the O ring must be replaced remove the existing one from its groove clean the groove carefully and lubricate it with protective grease film Assemble the new O ring into its groove and lubricate it with a protective grease film Assemble the new O ring into its groove and lubricate it with a protective oil film 1 Replace the O ring 48 of the head flange 49 2 Replace the O ring 50 of the ...

Page 37: ...he tube onto the piston taking care not to damaged the Teflon seal ring 53 the tube bevel has to smoothly compress the seal ring take care also not to damage the head flange O ring 50 5 Assemble the end flange by centring it on the inside diameter of the tube taking care not to damage the O ring 50 6 Assemble the nuts 25 onto the tie rods 18 Tighten the nuts to the recommended torque alternating b...

Page 38: ...7 Screw 8 Housing 9 Guide bar 10 Cover gasket 11 Yoke 12 Plug 13 Bushing 14 Guide block 15 Washer 16 Piston rod bushing 17 Piston rod 18 Tie rod 19 Piston 20 Stop setting screw 21 Cylinder tube 22 End flange 23 Nut 24 Spring washer 25 Nut 26 Plug 27 Guide rod 28 Spring thrust flange 29 Rod bushing 30 Container rod 31 Adaptor bush 32 Screw 33 Cover 34 Screw 35 Guide block pin 36 Vent valve 37 Slidi...

Page 39: ...0 C ASTM D 566 Product code 001A0065 Infosafe No ACISO GB eng C 35 Section 5 Maintenance 5 3 Lubrication of Mechanism For normal duty the scotch yoke mechanism of the actuator is lubricated for life In case of high load and high frequency of operation it may be necessary to periodically restore lubrication it is advisable to apply a generous coating of grease on the contact surfaces of the yoke an...

Page 40: ...present If the actuator can be operated it is essential to take it to fail safe position with the spring totally extended If actuator is still mounted onto the valve loosen the threaded connections between valve and actuator screws tie rods nuts Lift the actuator using the proper lifting points see Section 2 2 If the actuator needs storage before demolition see Section 2 3 WARNING The demolition o...

Page 41: ...oo slow Low supply pressure Restore Section 1 4 Wrong calibration of flow regulator valves Restore Section 3 6 Bad functioning of quick exhaust valve Wear of the valve Call Biffi Italia s r l Customer Service Actuator too fast High supply pressure Restore Section 1 4 Bad functioning of booster quick exhaust valve Call Biffi Italia s r l Customer Service Wrong calibration of flow regulator valves R...

Page 42: ...ffiI order confirmation concerning all the supply and serial number of the actuator Section 1 2 for any specific spare part for a specific actuator model Please send every spare parts request to Biffi Italia s r l Spares Office Tel 39 0523 944523 Fax 39 0523 941885 e mail Biffispares Emerson com Please specify 1 actuator model 2 Biffi acknowledgement 3 spare parts code 4 quantity 5 transport condi...

Page 43: ...g Bronze 3 2 Retainer ring Stainless steel 4 1 Housing Carbon steel 5 1 Guide bar Alloy steel 6 1 Yoke Carbon steel 7 1 Cover gasket Fiber 8 1 Guide block Carbon steel 9 1 Bushing Steel bronze Teflon 10 2 Sliding block Bronze 11 1 Vent valve Stainless steel 12 12 Screw Carbon steel 13 1 Cover Carbon steel 14 1 Guide block pin Alloy steel NOTE Recommended spare parts Figure 27 Scotch yoke mechanism...

Page 44: ...ated carbon steel 8 2 Guide sliding ring for piston Teflon graphite 9 1 Piston seal ring Teflone NBR rubber 10 4 Tie rod Alloy steel ASTM A320 gr L7 11 1 Stop setting screw Alloy steel 12 1 Cylinder tube Nickel plated carbon steel 13 1 End flange Carbon steel 14 1 Stop setting screw cover Carbon steel 15 4 Spring washer Carbon steel 16 4 Nut Carbon steel ASTM A194 gr 7 17 1 O ring NBR rubber 18 6 ...

Page 45: ...PVC 4 1 Stop setting screw Carbon steel 5 1 Spring container Carbon steel 6 1 Spring Carbon steel 7 1 Nut Carbon steel 8 1 Shoulder washer Alloy steel 9 1 Rod bushing Steel bronze Teflon 10 1 Guide rod Alloy steel chromium plated 11 1 Spring thrust flange Carbon steel 12 1 Rod bushing Steel bronze Teflon 13 1 Container rod Alloy steel chromium plated NOTE Recommended spare parts Figure 29 Spring c...

Page 46: ...v 5 Layouts 42 Section 7 Layouts Item Qty Description Material 1 6 Screw Teflon coated alloy steel 2 1 Gasket Fiber 3 1 Plug Carbon steel 4 1 Washer Carbon steel 5 4 Screw Alloy steel 6 1 Gasket Fiber NOTE Recommended spare parts Figure 30 Assembly kit Table 17 Parts List ...

Page 47: ...Installation Operation and Maintenance Manual MAN 608 Rev 5 December 2020 Layouts 43 Section 7 Layouts Figure 31 Hydraulic control unit MHP ...

Page 48: ...ural fiber 12 1 Handwheel Aluminum 13 1 Handpump 14 4 Screw Carbon steel 15 2 O ring Fluorosilicon rubber 16 1 O ring Fluorosilicon rubber 17 1 Check valve Carbon steel 18 1 Plug Stanless steel Teflon 19 1 Screw Carbon steel 20 1 Ball Stainless steel 21 1 Spring Carbon steel 22 2 Screw Stainless steel 23 1 Screw Stainless steel 24 1 Plug Stainless steel Teflon 27 3 Washer Carbon steel 28 2 Nut All...

Page 49: ...eat Carbon steel 6 1 Spring retainer ring Carbon steel 7 1 Fork Carbon steel 8 3 Pin Stainless steel 9 6 Retainer ring Carbon steel 10 1 Rod Alloy steel chromium plated 11 1 Body Carbon steel 12 1 Lever Carbon steel 13 1 Split pin with rope Carbon steel nylon 14 1 Threaded bush Aluminum 15 2 Rod seal ring Teflon graphite 16 2 O ring Fluorosilicon rubber 17 1 O ring Fluorosilicon rubber NOTE Recomm...

Page 50: ...nance Operations 46 Section 8 Date Report for Maintenance Operations Section 8 Date Report for Maintenance Operations Last maintenance operation date in factory on delivery exec by exec by exec by Next maintenance operation date exec by exec by exec by Start up date in factory on delivery on plant ...

Page 51: ...Installation Operation and Maintenance Manual MAN 608 Rev 5 December 2020 Notes This page intentionally left blank ...

Page 52: ...the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available on request We reserve the right to modify or improve the designs or specifications of our products at any time without notice Biffi Italia s r l Strada Biffi 165 29017 Fiorenzuola d Arda PC Italy T 39 0523 944 411 For complete list of sales and manufacturin...