Biffi Gigs 0.3 User manual

GIGS –Spring return direct gas actuator

Use and maintenance manual

Contents may change without notice

MAN 611

Use and mantenance manual

GIGS

SPRING RETURN DIRECT

GAS ACTUATOR

GIGS –Spring return direct gas actuator

Use and maintenance manual

Contents may change without notice

NOTE:

BIFFI Italia S.r.l pays the highest attention to collecting and verifying the

documentation contained in this user manual. However BIFFI Italia S.r.l. is not

liable for any mistakes contained in this manual, for damage or accidents due to

the use of the latter. The information contained is of exclusive reserved ownership

17/04/18

Updated Data-plate

Ermanni

Orefici

Vigliano

18/04/16

Updated applicable

regulation (chapter

1.1.1)

Ermanni

Orefici

Vigliano

16/04/13

Update chapter 5.1.1

Ermanni

Stoto

Vigliano

31/07/12

General update

Ermanni

Stoto

Vigliano

25/03/09

General update

Ermanni

Stoto

Vigliano

05/05/99

Document release

Lazzarini

Aliani

Ziveri

Rev.

Date

Description

Prepared

Checked

Approved

GIGS –Spring return direct gas actuator

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TABLE OF CONTENTS

1General warnings ................................................................ 4

1.1 Generalities.................................................................................4

1.1.1Applicable regulation...............................................................4

1.1.2Terms and conditions..............................................................4

1.2 Identification plate .......................................................................5

1.3 introducing the actuator...............................................................5

1.4 data sheet ...................................................................................6

2Installation........................................................................... 7

2.1 checks upon actuator receipt ......................................................7

2.2 actuator handling.........................................................................7

2.3 storage......................................................................................10

2.4 actuator assembly on the valve.................................................10

2.4.1Types of assembly ................................................................10

2.4.2Assembly procedure..............................................................15

2.5 pneumatic connections..............................................................16

2.6 electrical connections (if any)....................................................16

2.7 commissioning...........................................................................17

3Operation and use ............................................................. 18

3.1 operation description.................................................................18

3.2 residual risks .............................................................................22

3.3 operations .................................................................................22

3.3.1Local pneumatic operation....................................................22

3.3.2Local hydraulic manual operation..........................................23

3.3.3Remote operation..................................................................23

3.4 calibration of the angular stroke ................................................24

3.5 calibration of microswitches (if foreseen) ..................................26

3.6 calibration of the operation time ................................................32

4Operational tests and inspections...................................... 33

5Maintenance ...................................................................... 34

5.1 periodic maintenance................................................................34

5.1.1Check and restore oil level in the gas-hydraulic tanks...........35

5.2 Extraordinary maintenance .......................................................36

5.2.1Replacing the seals ..............................................................36

5.3 Dismantling and demolition........................................................42

5.4 Lubrication of mechanism..........................................................43

6Troubleshooting ................................................................ 44

6.1 failure or breakdown research...................................................44

7Layouts.............................................................................. 45

7.1 Spare parts order ......................................................................45

7.2 parts-list for maintenance and replacing procedure...................46

8 Date report for maintenance operations ............................ 55

GIGS –Spring return direct gas actuator

Use and maintenance manual

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1General warnings

The manual is an integral part of the machine, it should

be carefully read before carrying out any operation and

it should be kept for future references.

1.1 GENERALITIES

BIFFI Italia S.r.l actuators are conceived, manufactured and

controlled according to the Quality Control System in compliance with

EN-ISO 9001 international regulation.

1.1.1 Applicable regulation

EN ISO 12100:2010: Safety 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

1.1.2 Terms and conditions

Biffi Italia srl guarantees that all the items produced are free of

defects in workmanship and manufacturing materials and meet

relevant current specifications, provided they are installed, used and

serviced according to the instructions contained in the present

manual. The warranty can last either one year from the date of

installation by the initial user of the product, or eighteen months from

the date of shipment to the initial user, depending on which event

occurs first. All detailed warranty 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 conditions, the repairs will be charged

according to applicable fees. The warranty and Biffi Italia srl

liability shall lapse in the event that any modification or

tampering whatsoever be performed on the actuator.

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1.2 IDENTIFICATION PLATE

It is forbidden to modify the information and the marks without

previous written authorization by BIFFI Italia S.r.l.

The plate fastened on the actuator contains the following

information (Figure1).

Figure 1 –Data plate

1.3 INTRODUCING THE ACTUATOR

The direct gas actuator GIGS was engineered and is manufactured

to provide fail safe operation for any quarter turn application such as

ball, plug, butterfly valves or dampers, in both On-Off and Modulating

heavy duty service.

The actuator (see figure 2) is made up of a weatherproof scotch yoke

mechanism transforming the linear movement of the pneumatic

cylinder (on closing or opening) into the rotary movement, which is

necessary for operation. The spring module incorporates up to four

springs, fully encapsulated in a factory-welded cartridge: this ensure

safety to personnel and simplifies assembly. The spring action can

be easily changed in the field from “to close” in “to open” or vice-

versa. The angular stroke of the yoke is adjustable between 82° and

98° by means of the external mechanical stops screwed into the left

wall of the mechanism housing and into the end flange of the

pneumatic cylinder. The 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

GIGS –Spring return direct gas actuator

Use and maintenance manual

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to the valve either directly or, if required, with the interposition of an

adaptor flange or a mounting bracket. The actuator yoke has a hole

with keyways suitable for the assembly of an insert bush the internal

hole of which is machined (by BIFFI or at Customer's care),

according to the shape and dimensions of the valve stem. BIFFI can

supply different types of control system following Customer's

requirements.

The expected lifetime of actuator is approximately 25 years .

Figure 2 –Identification of actuator parts

1.4 DATA SHEET

Supply fluid

Natural gas, compressed air, nitrogen

Operating temperature

Standard: from –30°C to +100°C

Optional: from –60° to +140°C

Supply pressure

Please refer to technical document:

“actuator data-sheet”

Spring cartridge

Pneumatic cylinder

Scotch-yoke

mechanism

Valve coupling

Valve position indicator

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2Installation

2.1 CHECKS UPON ACTUATOR RECEIPT

❑Check that the model, the serial number of the actuator and the

technical data reported on the identification plate correspond with

those of order confirmation (Sect. 1.2).

❑Check that the actuator is equipped with the fittings as provided for

by order confirmation.

❑Check that the actuator was not damaged during transportation: if

necessary renovate the painting according to the specification

reported on the order confirmation.

❑If the actuator is received already 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 (Sect. 3.4) and of micro-switches (if any) (Sect.

3.5).

2.2 ACTUATOR HANDLING

The lifting and handling of the actuator must be done by

qualified personnel and in accordance with the laws and

regulations in force. Avoid the lifted actuator to be hung

above the personnel.

The actuator must be lifted by means of a suitable lifting

apparatus. The weight of the actuators is indicated in

the technical documentation attached to the equipment

itself.

For lifting and moving the actuator, use only hooks

fitted with safety latch, like the one, for example, shown

in follow figure 2.1

Picture 2.2 –Lifting points for GIGS actuators

Figure 2.1 Example of hook with

safety latch

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1-2 = Lifting points ( obligatory ) 3 = Balancing point

1 = point of support - 2 = supports for lateral positioning

3 = don’t lay the actuator on tie-rods of cylinder /s and

don’t lay the actuator on accessories ( manual override,

pneumatic control group etc. )

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•For lifting unbalanced loads, use ropes of different lengths or

chains with adjustable length.

•Check each time the conditions of all lifting 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

load shifting sideways in an uncontrolled manner.

•Use slings of such length that the angles of the leg from

vertical are as narrow as possible (MAX < 20°).

•During handling, do not transport the suspended actuator

above staff members in charge of the operation.

DO NOT USE the lifting eyelets on actuator to lift valve +

actuator assembly

Figure 2.3

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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 closed.

If the storage is long-term or outdoor:

❑Keep the actuator protected from direct weather conditions.

❑Replace plastic plugs of pneumatic and electrical connections (if

any) with metal plugs that guarantee perfect tightness.

❑Coat with oil, grease or protection disc, the valve coupling area.

❑Periodically operate the actuator (Sect. 3.3).

2.4 ACTUATOR ASSEMBLY ON THE VALVE

2.4.1 Types of assembly

For coupling to the valve, the housing is provided with a flange with

threaded holes according to Biffi standard tables (SCN6200

SCN6201). The number, dimensions and diameter of the holes are

made in accordance with ISO 5211, but for actuator models 0.3 to 6

the holes are drilled on the centreline in order to allow an easier

assembly of an intermediate 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 Biffi standard tables SCN6200

and SCN6201.

GIGS –Spring return direct gas actuator

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GIGS –Spring return direct gas actuator

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GIGS –Spring return direct gas actuator

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If required, for the standard models size 0.3 to 6, Biffi can supply an

insert bush with un-machined bore in accordance with Biffi standard

table SCN6202 enclosed ( see following pages ). On request the

insert bush bore can be machined by Biffi to couple the valve stem,

provided its dimensions match the maximum stem acceptance of the

bush according to Biffi doc.: TN1005. The particular execution of the

flange and bushing allow the actuator to be rotated by 90° in 4

different positions according to the following figure:

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Position 2 Position 3 Position 4

Rotate insert-bush

180° around vertical-

standard position (1)

Rotate insert-bush 180°

around axis A-A, from

position 2

Rotate insert-bush

180° around axis A-A

from position 1

Insert bush turned upside down

Figure 3 –Insert bush + intermediate coupling flange

The Biffi insert bush with 2 external keys at 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.

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2.4.2 Assembly procedure

Failure to comply with the following procedures may impair

product warranty.

Installation, commissioning and maintenance and repair works

should be carried out by qualified staff.

A non-conforming assembly could be the source of serious

accidents.

For actuator assembly on the valve:

Check that the assembly position, as shown on the

documentation, complies with system’s geometry.

Check the consistency of the parts of actuator-valve coupling.

❑Operate the actuator so that it reaches the position matching valve

position (Section 3.3).

❑Lubricate valve stem with oil or grease.

❑Properly clean and remove grease from coupling flange surfaces.

❑Connect, if supplied separately, the adjustment insert to valve stem

and fasten it with the special fastening pins.

❑Lift the actuator using the special lifting points (Sect. 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 connections (screws, tie

rods, nuts). If holes of coupling flanges are not aligned, adequately

operate the actuator if necessary move the mechanical stops

backwards (Sect. 3.4).

❑Fasten threaded connections. Please refer to Table 1.

Table 1: nuts tightening torque

Threading

Tightening torque

(Nm)

M10

M12

M14

110

M16

160

M20

320

M22

420

M24

550

M27

800

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M30

1100

M33

1400

M36

1700

The screwing values in Table 1 were calculated considering the

materials ASTM A320 L7 for screws or tie rods and ASTM A194

gr.2H for the nuts.

2.5 PNEUMATIC CONNECTIONS

Check that the values of pneumatic supply available are

compatible with those reported on the identification plate of the

actuator.

The connections should be made by qualified staff.

Use pipes and connections appropriate as for type, material and

dimensions.

❑Properly de-burr the ends of rigid pipes

❑Properly clean the interior of pipes sending through them plenty of

the supply fluid used in the system.

❑Mould and fasten the connection pipes so that no irregular strains at

entries or loosening of threaded connections occur.

❑Make the connections according to the operating diagram.

❑Check the absence of leakages from pneumatic connections.

2.6 ELECTRICAL CONNECTIONS (IF ANY)

Use components appropriate as for type, material and

dimensions

The connections should be made by qualified staff

Before carrying out any operation, cut line power off

Safety provisions :

2006/95/EC: Directive for low voltage equipment (until 19 April

2016) 2014/35/EU from 20 April 2016

2004/108/EC: Directive for the electromagnetic compatibility

(until19 April 2016) 2014/30/EU from 20 April 2016

94/9/CE: Directive and safety instructions for use in hazardous

area (until 19 April 2016) 2014/34/EU from 20 April 2016

Remove plastic plugs from cables entries

❑Screw firmly the cable glands.

❑Introduce connection cables.

❑Make the connections in compliance with applicable wiring diagrams

on the documentation supplied.

❑Screw the cable gland.

❑Replace the plastic plugs of unused entries with metal plugs.

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Picture 2 –Junction box on Control group (if foreseen)

2.7 COMMISSIONING

Check that values of electrical supply to the control group

( if foreseen ) are compatible with those on the plate on the

junction box (Picture 2).

Installation, commissioning and maintenance and repair

works should be made by qualified staff.

Upon actuator commissioning please carry out the following checks:

❑Check that the pressure and quality of the gas supply (filtering

degree, dehydration) are as prescribed. Check that the feed voltage

values of the electric components (solenoid valve coils, micro-

switches, pressure switches, etc.) are compatible with those

reported on the identification plate of the actuator (Figure 1).

❑Check that the setting of the components of the actuator control unit

(pressure regulator, pressure switches, flow control valves, etc.)

meet the plant requirements.

❑Check that paint is not be damaged during transport, if necessary

repair the damages to paint coat.

❑Carry out all kinds of operations and check their proper execution

(Sect. 3.3).

❑Check the absence of leakages in the pneumatic connections.

If necessary tighten the nuts of the pipe-fittings

❑Check proper operation of all the due signalling ( valve position, gas

supply pressure etc. )

❑Make a complete functional test in order to verify all the operations

are executed according to operating schematic diagram supplied.

Ground

GIGS –Spring return direct gas actuator

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3Operation and use

3.1 OPERATION DESCRIPTION

In the normal operating situation, the direct gas actuator is fed by

pressurised gas which flows into pneumatic cylinder. The cylinder

piston stroke causes the actuator operation and the consequent

valve movement to the operational position requested (for example to

the “open” position).

Upon a demand, the gas is discharged from the cylinder into the

return line: the actuator performs the closing operation driven by the

spring movement, and the valve moves from the open position to the

close (safety-related) position.

For local or remote operations, please refer to par. 3.3.1 , 3.3.2 ,

3.3.3 and 3.34 and prior to technical documentation furnished with

actuators.

Typical schematics for various applications are follow attached for

information only. As shown in these schematics, actuator operation

speed (see chapt. 3.5) is adjustable by unidirectional flow regulators

(item 278) ( refer to follow GIGS typical control schematics ) ;

For all the relevant information please refer to the specific

documentation supplied.

GIGS –Spring return direct gas actuator

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Typical control schematics

Spring return direct gas actuator with local / remote

controls

GIGS –Spring return direct gas actuator

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Spring return direct gas actuator with manual

override - local / remote controls

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