BIFFI RPHD User manual

RPHD –Double acting hydraulic actuator
Use and maintenance manual
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MAN 623
Use and maintenance manual
RPHD
DOUBLE ACTING
HYDRAULIC ACTUATOR
3
18/04/16
Updated applicable
regulation (chapter 1.1.1)
Ermanni
Orefici
Vigliano
2
20/10/14
Updated chapters
1.1.2 and 5.4
Ermanni
Cristalli
Vigliano
1
11/12/09
General update
Ermanni
Stoto
Vigliano
0
05/05/99
Document release
Lazzarini
Aliani
Ziveri
Rev.
Date
Description
Prepared
Checked
Approved

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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...................................................................................9
2.4 ACTUATOR ASSEMBLY ON THE VALVE ...............................10
2.4.1Types of assembly ................................................................10
2.4.2Assembly procedure..............................................................12
2.5 HYDRAULIC CONNECTIONS..................................................13
2.6 ELECTRICAL CONNECTIONS (IF ANY)..................................13
2.7 COMMISSIONING ....................................................................14
3Operation and use ............................................................. 15
3.1 OPERATION DESCRIPTION....................................................15
3.2 RESIDUAL RISKS.....................................................................17
3.3 OPERATIONS...........................................................................17
3.4 CALIBRATION OF THE ANGULAR STROKE ..........................17
3.5 CALIBRATION OF MICROSWITCHES (if foreseen).................19
3.5 CALIBRATION OF THE OPERATION TIME.............................21
4Operational tests and inspections...................................... 22
5Maintenance ...................................................................... 23
5.1 PERIODIC MAINTENANCE......................................................23
5.2 EXTRAORDINARY MAINTENANCE ........................................25
5.3 DISMANTLING AND DEMOLITION...........................................29
6Troubleshooting ................................................................ 29
6.1 FAILURE OR BREAKDOWN RESEARCH ...............................30
7Layouts.............................................................................. 31
7.1 Spare parts order ......................................................................31
7.2 parts-list for maintenance and replacing procedure...................32
8 Date report for maintenance operations ............................ 34

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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
of BIFFI Italia S.r.l and may be modified without prior notice. All rights reserved.

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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
UNI EN ISO 12100-1: 2005: Safety of machinery –Basic notions,
general design principles. Part 1-Basic terminology, method.
UNI EN ISO 12100-2: 2005: Safety of machinery –Basic notions,
general design principles. Part 2-Technical principles and
specification.
2006/42/EC: Machine directive.
97/23/EC: Directive for pressure PED equipment (until 18 July
2016) 2014/68/EU from 19 July 2016
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
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

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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.
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
RPHD are hydraulic high-pressure double acting actuators, suitable
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 rack and pinion
mechanism, which transforms the linear movement of the hydraulic
cylinder (on closing or opening), into the rotary movement for the
valve operation. The surfaces of the pinion and rack are treaded to
guarantee a low friction and a long life. External travel stops allow
precise angular stroke adjustment between 80° and 100°.
Totally enclosed, weatherproof housing, made of nodular cast iron for
maximum strength and suitable for use in hostile environments.
The actuator is assembled onto the valve by connecting the actuator-
housing flange to the valve flange by a spool piece and the actuator
shaft to the valve stem by a stem extension.

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The mounting flange, on the housing top, can be utilised for the
assembly of limit switches, position transmitter, positioner etc., which
are actuated by the actuator output shaft.
The actuator housing is provided, on the front face and in the rear
face (optional), with threaded holes for the assembly of accessories
(control panels, air storage tank, etc.).
The expected lifetime of actuator is approximately 25 years .
Figure 2 –Identification of actuator parts
1.4 DATA SHEET
Supply fluid
Hydraulic oil or fire-resistant fluid
Operating temperature
Standard: from –30°C to +100°C
Optional: from –60° to +140°C
Design pressure
Supply pressure
Max operating torque
Design pressure of the cylinder 220 barg
Please refer to technical document:
“actuator data-sheet”
Up to 2600 Nm
Hydraulic cylinders
weatherproof
housing
Actuator shaft for
coupling with valve
Rack and
pinion
mechanism
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 should be made by qualified staff
and in compliance with the laws and provisions in force.
The fastening points are appropriate for the lifting of the
actuator alone and not for the valve + actuator assembly.
Avoid that during the handling, the actuator passes above
the staff.
The actuator should be handled with appropriate lifting
means. The weight of the actuator is reported on the
delivery bill.

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Pictures 1-2 : Lifting and storage method
1-2= lifting points (obligatory)

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1 = point of support (lifting points)
2= don’t lay the actuator on tie-rods
Don’t lay the actuator on accessories ( manual hand-pump,
manual jack-screw, hydraulic control group etc. )
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 hydraulic and
electrical connections (if present).
❑Check that the protection of the control system 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 hydraulic 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).

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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 (TN1312 attached).
The number, dimensions and diameter of the holes are made in
accordance with ISO 5211.The actuator is provided with a spool
piece and a stem extension for coupling to the valve. The assembly
position of the actuator, with reference to the valve, must comply with
the plant requirements (cylinder axis parallel or perpendicular to the
pipeline axis).
Important:
To fix the actuator to the valve flange must be used
the stud bolts and nuts supplied by BIFFI!
In case the actuator is supplied without stud bolts
and nuts the following materials must be used as a
minimum:
ASTM A 193 Grade L7 for Stud Bolts
ASTM A 194 Grade 4 for Nuts
.

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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 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 (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)
M8
20
M10
40
M12
70
M16
160

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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 HYDRAULIC CONNECTIONS
Check that the values of hydraulic supply available in
the system 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.
Use motor fluid with purity degree ISO 4406 17/14 or
NAS 1638 Class 8 (AS4059 Class 4B-F).
For special applications the lower contamination
degree is required. Please refer to the documentation
supplied.
❑Properly burr the ends of rigid pipes if present.
❑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 functional diagram.
❑Check the absence of leakages from hydraulic connections.
For the characteristics of the motor fluid please refer
to the documentation supplied.
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 as per CEI 64-8 regulation should
be complied with (same as IEC 60364).

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❑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 plugs of unused entries with metal plugs.
2.7 COMMISSIONING
Installation, commissioning and maintenance and
repair works should be made by qualified staff.
Any calibration relative to functional aspects of the
actuator are preset at the factory.
Before any modifications please read BIFFI Italia S.r.l.
Upon actuator commissioning please carry out the following checks:
❑Check that the values of hydraulic supply available in the system
are compatible with those reported on the identification plate of
the actuator (Figure 2) and on the documentation supplied.
❑Check the power voltage of electrical components complies with
the one reported on the documentation supplied.
❑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 kinds of operations and check their proper execution
(Sect. 3.3).
Check the proper operation of all the warnings

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3Operation and use
3.1 OPERATION DESCRIPTION
The oil supply pressurizes the hydraulic cylinder chamber relevant to
the operation to carry out (opening or closing) (see following pages).
This pressure starts the linear motion of the piston and the
consequent rotation motion of the rack and pinion mechanism, to
which the valve stem is coupled. Pressurize the other cylinder
chamber to return at the starting 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 : in these schematic ,actuator operation in local is
performed by the optional hydraulic manual override (example A)
Actuator operation in remote shall be performed operating the
hydraulic manual selector (item 3 of example B) by control signal
from control room
The power and control systems are supplied on specific customer
demand ( refer to specific documentation furnished)
Wrench for local
manual operation
(Optional *)
Hydraulic manual
override (Optional *)

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3.2 RESIDUAL RISKS
The actuator has parts under pressure. Use the due caution.
Use the due caution.
Use individual protections provided for by the laws and
provisions in force.
3.3 OPERATIONS
The operations are carried out sending the proper signal through the
control system in compliance with Customer specifications.
Please refer to the functional diagram and specific documentation
supplied.
3.4 CALIBRATION OF THE ANGULAR STROKE
Two mechanical stoppers are available for external stroke
adjustment between 80° and 100° rotation.
It is important that the mechanical stops of the actuator (and not
those of the valve) stop the angular stroke at both extreme valve
position (fully open and fully closed), except when this is required by
the valve operation (e.g. metal seated butterfly valves).
The setting of the open valve position is performed by adjusting the
travel stop screw, which is on the left side of the actuator (screwed
into the end flange of the hydraulic cylinder).
The setting of the closed valve position is performed by adjusting the
travel stop screw, which is on the right side of the actuator (screwed
into the end flange of the hydraulic cylinder).

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For the adjustment of the travel stop screw in the end flange of the
hydraulic cylinder proceed as follows:
1) Unscrew the plug from the cylinder end flange.
2) If the actuator angular stroke is stopped before reaching the end
position (fully open or closed), unscrew the stop screw by turning it
anticlockwise with an Allen wrench until the valve reaches the
correct position.
3) If the actuator angular stroke is stopped beyond the end position
(fully open or closed valve), screw the stop screw by turning it
clockwise until the valve reaches the correct position.
4) Screw the plug into the cylinder end flange.
HYDRAULIC
CYLINDER
DIAMETER
WRENCH
C1
(mm)
WRENCH
C2
(mm)
From 28
To 40
8
22
From 45
To 60
12
27
From 70
To 175
14
36
From 200
To 235
22
36

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3.5 CALIBRATION OF MICROSWITCHES (IF FORESEEN)
Operate only the micro-switches corresponding to the
direction of operation being carried out, as clearly
reported on the micro-switch.
Micro-switches are placed inside a special box (Picture 9).
For micro-switches calibration please refer to the relative wiring
diagram and follow these steps:
❑Unscrew the fastening screws of the cover (Picture 9).
❑Remove the cover paying attention not to deteriorate the gasket
and the cylindrical and flat coupling surfaces.
❑Operate the actuator (in opening or closing) with local pneumatic
or hydraulic operation (Section 3.3)
❑Unscrew the screw of the operating cam relative to the micro-
switch to calibrate and adjust it according to the settings (Picture
10).
❑Tighten the screw.
❑Operate the actuator and adjust any other micro-switch with the
procedure already described.
❑Position the cover making sure the cam-carrier shaft grips with
the index dragging shaft.
❑Check that the cover and the index show the proper position of
the valve (Picture 11).
❑Tighten the screws.
Picture 9 –Micro-switches
box
Picture 10 –Cam adjustment

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If the index (Picture 11), does not signal the proper position of the
valve but is turned by 90°:
❑Remove the roll pin placed on the position indicator (index).
❑Turn the indicator until reaching its proper positioning.
❑Put the roll pin back in its position.
End of stroke microswitches should be operated
before the stop of the stroke of the actuator due to
mechanical stops. Adjust the relative cams properly.
pin
Picture 11 –Position indicator and pin for
micro-switches box
Position
indicator
(index)