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GILS –Spring return direct gas linear actuator

Use and maintenance manual

Contents may change without notice

MAN 726

Use and maintenance manual

GILS

SPRING RETURN DIRECT

GAS LINEAR ACTUATOR

18/04/16

Updated applicable

regulation (chapter 1.1.1)

Ermanni

Orefici

Vigliano

09/11/15

Document release

Ermanni

Orefici

Vigliano

Rev.

Date

Description

Prepared

Checked

Approved

GILS –Spring return direct gas linear actuator

Use and maintenance manual

Contents may change without notice

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..............................................................................7

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

2.1 CHECKS UPON ACTUATOR RECEIPT.....................................7

2.2 ACTUATOR HANDLING.............................................................8

2.3 STORAGE...................................................................................9

2.4 ACTUATOR ASSEMBLY ON THE VALVE .................................9

2.4.1Types of assembly ..................................................................9

2.4.2Assembly procedure..............................................................10

2.5 PNEUMATIC CONNECTIONS..................................................13

2.6 ELECTRICAL CONNECTIONS (IF ANY)..................................14

2.7 COMMISSIONING ....................................................................15

3Operation and use ............................................................. 16

3.1 OPERATION DESCRIPTION....................................................16

3.2 RESIDUAL RISKS.....................................................................16

3.3 OPERATIONS...........................................................................16

3.4 CALIBRATION OF THE linear STROKE...................................19

3.5 CALIBRATION OF MICROSWITCHES (applicable for BIFFI limit

switch box* ONLY)...........................................................................21

3.6 CALIBRATION OF THE OPERATION TIME .............................23

4Operational tests and inspections...................................... 24

5Maintenance ...................................................................... 25

5.1 PERIODIC MAINTENANCE......................................................25

5.2 EXTRAORDINARY MAINTENANCE ........................................30

5.3 DISMANTLING AND DEMOLITION...........................................32

6Troubleshooting ................................................................ 33

6.1 FAILURE OR BREAKDOWN RESEARCH ...............................33

7Layouts.............................................................................. 34

7.1 Spare parts order ......................................................................34

7.2 parts-list for maintenance and replacing procedure...................35

8Date report for maintenance operations.................................. 44

GILS –Spring return direct gas linear 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

GILS –Spring return direct gas linear actuator

Use and maintenance manual

Contents may change without notice

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

were modified or repaired by unauthorized staff. In the event that a

GILS –Spring return direct gas linear actuator

Use and maintenance manual

Contents may change without notice

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

GILS Spring return pneumatic high-pressure linear actuators, are

suitable for the operation of linear valves ( wedge gate valves,

through conduit gate valves) for ON-OFF and modulating heavy-duty

service.

The actuator is made up of a pneumatic cylinder and a mounting

pedestal complete with a joint for the coupling to the valve stem of

actuator output stem. The valve is actuated in opening and in closing

position by the actuator pneumatic cylinder that is pressurized in one

direction and by Spring cartridge, in the other direction.

The spring module incorporates up to four springs, fully encapsulated

in a factory-welded cartridge: this ensure safety to personnel and

simplifies assembly. The linear stroke of the valve is adjustable by

means of the external mechanical stop for upward position and by

the adjustment of the coupling of valve stem to actuator joint for the

downward position.

GILS –Spring return direct gas linear actuator

Use and maintenance manual

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The actuator pedestal has a flange with threaded holes to fix the

actuator to the valve.

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 –and actuator code :

GILS –Spring return direct gas linear actuator

Use and maintenance manual

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1.4 DATA SHEET

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).

Supply fluid

Air, nitrogen or sweet gas

Operating temperature

Standard: from –30°C to +100°C

Optional: from –60° to +140°C

Supply pressure

From 10 to 105 bar g Maximum

GILS

Spring return linear actuator

GILS –Spring return direct gas linear actuator

Use and maintenance manual

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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 Lifting 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.

Picture 1 –Lifting points for GILS

GILS –Spring return direct gas linear actuator

Use and maintenance manual

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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

GILS –Spring return direct gas linear actuator

Use and maintenance manual

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The adapter pedestal in fabricated carbon steel is specifically

designed for adaptation to any type of valve with provision for local

indicator, limit switches and other accessories (on request).

Lift the actuator by safety-hook for chains using the lifting-points (see

sect. 2.2) on the top of actuator for handling, transporting and

assembling in vertical position (see picture 1). For handling,

transporting and assembling the actuator in horizontal position by

safety-hook for chains use the lifting-points on the top of cylinder

head-flange and on coupling flange (see picture 2).

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.

A) TO ASSEMBLE THE ACTUATOR ONTO THE VALVE BY BRACKET

WITH THREADED JOINT PROCEED AS FOLLOWS:

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