Biffi Pneumatic Actuators, Models Alga/Algas/Algas-QA

40 Pages·2015·2.99 MB·English

bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
1. General warninGs installation, maintenance or use, or by irregular
working conditions, the repairs will be charged
Important according to applicable fees.
The manual is an integral part of the machine,
it should be carefully read before carrying out The warranty and Biffi Italia S.r.l. liability
any operation and it should be kept for future shall lapse in the event that any modification
references. or tampering whatsoever be performed on
the actuator.
1.1 GEnEraLItIES
Biffi italia s.r.l. actuators are conceived,
manufactured and controlled according to the
Quality Control system in compliance with
tabLE of contEntS en isO 9001 international regulation.
1 General warnings ..........................................1 1.1.1 applicable regulation
en isO 12100-1: 2005: safety of machinery
2 installation .....................................................3 – Basic notions, general design principles.
part 1-Basic terminology, method.
3 Operation and use .........................................7 en isO 12100-2: 2005: safety of machinery
– Basic notions, general design principles.
4 Operational tests and inspections..............23 part 2-Technical principles and specification.
2006/42/eC: Machine directive.
5 Maintenance. ...............................................23 97/23/eC: Directive for pressure peD
equipment.
6 Troubleshooting ..........................................30 2006/95/eC: Directive for low voltage
equipment.
7 layouts .........................................................30 2004/108/eC: Directive for the electromagnetic
compatibility.
8 Date report for maintenance operations ...39 94/9/eC: Directive and safety instructions for
use in hazardous area.
1.1.2 terms and conditions
Biffi italia s.r.l. 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,
notE depending on which event occurs first. all
Biffi italia s.r.l. pays the highest attention to collecting detailed warranty conditions are specified in
and verifying the documentation contained in this the documentation forwarded together with the
user manual. However Biffi italia s.r.l. is not liable product. This warranty does not cover special
for any mistakes contained in this manual, for products or components not warranted by
damage or accidents due to the use of the latter. subcontractors, or materials that were used
The information contained is of exclusive reserved or installed improperly or were modified or
ownership of Biffi italia s.r.l. and may be modified repaired by unauthorized staff. in the event
without prior notice. that a fault condition be caused by improper
www.pentair.com/valves © 2012 pentair plc. all rights reserved. VcIom-03129-En 15/05
bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
The actuator (see figure 2) is made up of 1.4 Data ShEEt
a weatherproof scotch yoke mechanism
transforming the linear movement of the supply fluid air, nitrogen or sweet gas, special
pneumatic cylinder (on closing or opening) into version available for sour gas
the rotary movement, which is necessary for Operating standard: from –30°C to +100°C
operation. The angular stroke of the yoke is temperature Optional: from –60° to +200°C
adjustable between 82° and 98° by means of supply pressure please refer to technical
the external mechanical stops screwed into the document: 'actuator data sheet'
left wall of the mechanism housing and into the Output torque up to 750,000 nm
end flange of the pneumatic cylinder. The cover (higher value with special version)
of the scotch yoke mechanism is arranged
for the assembly of the required accessories
fIGurE 1 - Data plate (positioner, signalling limit switches, position
transducer, etc.) by means of proper matching
units. The above mentioned accessories are
1.2 IDEntIfIcatIon pLatE operated by the actuator drive sleeve. The
housing of the scotch yoke mechanism has a
it is forbidden to modify the information and the flange with threaded holes to fix the actuator to
marks without previous written authorization by the valve either directly or, if required, with the
Biffi italia s.r.l. interposition of an adaptor flange or a mounting
The plate fastened on the actuator contains the bracket. The actuator yoke has a hole with
following information (figure 1). keyways suitable for the assembly of an insert
bush the internal hole of which is machined
1.3 IntroDucInG thE actuator (by Biffi or at customer's care), according to
the shape and dimensions of the valve stem.
The alGa actuator is engineered and Biffi can supply different types of control
manufactured to provide maximum torque system following customer's requirements.
output with minimum supply pressure. The expected lifetime of actuator is
alGa actuators are suitable for the operation approximately 30 years.
of any quarter turn operation such of ball, plug,
butterfly valves or dampers, in both On-Off and
Modulating heavy duty service.
Manual hand pump - MHp
Control system (optional) (optional)
Valve position indicator
pneumatic cylinder scotch yoke mechanism Hydraulic cylinder for alGa-MHp models
or second pneumatic cylinder for alGa*2
Valve coupling
double cylinder models (optional)
fIGurE 2 - identification of actuator parts
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bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
2. insTallaTiOn
2.4 actuator aSSEmbLy on thE VaLVE fIGurE 3a, 3b - lifting points for alGa / alGa-
MHp / alGa-MsJ actuators.
2.1 chEckS upon actuator rEcEIpt 2.4.1 types of assembly
For coupling to the valve, the housing is 3a
• Check that the model, the serial number of provided with a flange with threaded holes
the actuator and the technical data reported according to Biffi standard tables (sCn6200;
on the identification plate correspond with sCn6200-1; sCn6201; sCn6201-1). The
those of order confirmation (par. 1.2). number, dimensions and diameter of the
• Check that the actuator is equipped with the holes are made in accordance with isO 5211,
fittings as provided for by order confirmation. but for actuator models 0.3 to 6 the holes are
• Check that the actuator was not damaged drilled on the centerline in order to allow an
during transportation: if necessary renovate easier assembly of an intermediate flange,
the painting according to the specification when required. This intermediate flange (or
reported on the order confirmation. spool-piece) can be supplied when the valve
• If the actuator is received already assembled flange can not directly match the actuator
with the valve, its settings have already been flange in its 'standard' configuration. For the
made at the factory. biggest actuator models, the actuator flange
if the actuator is delivered separately can be machined in accordance with the valve
from the valve, it is necessary to check, flange dimensions.
and, if required, to adjust, the settings The yoke has bored with keyways for coupling
of the mechanical stops (par. 3.3) and of to the valve stem, the dimensions of which are
microswitches (if any) (par. 3.4). according to Biffi standard tables sCn6200-
and sCn6201 (see next pages).
2.2 actuator hanDLInG
1, 2 = lifting points (obligatory)
Important 3 = Balancing point
The lifting and handling should be made by
qualified staff and in compliance with the laws and
provisions in force.
3b
WarnInG
The fastening points are appropriate for the lifting
of the actuator alone and not for the valve and
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.
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). 1 = point of support
• Check that the cover of the control group and 2 = supports for lateral positioning
of the limit switch box (if any) are properly
closed. WarnInG
if the storage is long-term or outdoor: 3 = Don’t lay the actuator on tie rods of cylinder /s
• Keep the actuator protected from direct and don’t lay the actuator on accessories (manual
weather conditions. hand pump, manual jackscrew, pneumatic control
• Replace plastic plugs of pneumatic and group etc.)
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 (par. 3.3).
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bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
fIGurE 4a fIGurE 4b
aCTuaTOr MODels 0.3 TO 6 aCTuaTOr MODels 14 TO 42
Drive sleeve
max Drive sleeve H max
H +0.5h₁0 +0.5h₁0
Ø d₂+00.1 Ø d₄
Ø d₂+0.1 Ø d₄ h₂ Ø d₃±0.2 ₂h
Ø d₃±0.2 Ø d₁ max
Ø d₁ max n. threaded holes
e pcd, number and size according to Iso 5211
g
n. threaded holes an 'w'D10
n.8 holes flange w D10 K0+0.4 p(inbcsudtte ,t anhdue mohFfob lsleoetrrs awa dandr dell e ison itnzhee ec ae ccnectnoetrreldirinnliegn et)o Iso 5211 en.12 holes fl Ø d₅++00..21 +0,40K Flow line
g
n
e a
4 holes flang Ø d₅++00.2.1 45º n.16 holes fl
n.
Top view of the scotch yoke mechanism
(actuator shown in closed position)
Top view of the scotch yoke mechanism
(actuator shown in closed position)
coupLInG DImEnSIonS moDELS 0.3 to 0.6 (mm)
actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ n h₁ h₂ h max Ø d₅ W k
0.3 240 93 165 M20 4 5 17 127 70 12 75.6
0.9 310 112 254 M16 8 5 19 150 86 14 96.6
1.5 360 144 298 M20 8 6 19 190 112 18 119
3 430 195 356 M30 8 9 23 200 157 25 167.8
6 520 250 406 M36 8 14 29 260 200 28 212.8
coupLInG DImEnSIonS moDELS 14 to 42 (mm)
actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ n h₁ h₂ h max Ø d₅ W k
14 580 250 483 M36 12 10 29 340 175 45 195.8
18 680 290 603 M36 16 12 32 350 200 45 220.8
32 780 290 603 M36 16 12 32 400 220 50 242.8
35 780 315 603 M36 16 11 32 400 240 50 242.8
42 840 310 603 M36 16 12 32 400 220 50 242.8
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bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
fIGurE 4c fIGurE 4D
aCTuaTOr MODels 50 anD 60 inserT BusH + inTerMeDiaTe COuplinG FlanGe
Drive sleeve Housing Drive sleeve
max
H
+0.5h₁0
Ø d₂+00.1 Ø d₄ insert bush adaptor flange
Ø d₃±0.2 h₂
Ø d₁ max e
g
an Standard position 1
n. threaded holes s fl
e
Flange sizing according to Iso 5211 hol
8
'w'D10 n. Flow line
e
g
an Drive sleeve
s fl
Ø d₅++00.2.1 +0,40K Flow line 4 hole
n.
insert bush
Top view of the scotch yoke mechanism
(actuator shown in closed position)
position 2 position 3 position 4
coupLInG DImEnSIonS moDELS 50 anD 60 (mm)
actuator model Ø d₁ Ø d₂ Ø d₃ Ø d₄ n h₁ h₂ h max Ø d₅ W k
50 800 315 698 M36 24 10 32 430 240 56 264.8
60 840 315 698 M36 24 10 32 430 240 56 264.8
if required, for the standard models size The Biffi insert bush with 2 external keys at 45°
0.3 to 6, Biffi can supply an insert bush with allows to position the keyway for the valve every
un-machined bore in accordance with Biffi 90°. Consequently actuator can be mounted
standard table sCn6202. On request the insert in 4 positions at 90° on top of the valve. For
bush bore can be machined by Biffi to couple biggest actuator models, the bore of the yoke
the valve stem, provided its dimensions match can be machined according to the dimensions
the maximum stem acceptance of the bush of valve stem.
according to Biffi doc.: Tn1005. The particular
execution of the flange and bushing allow the position 2 position 3 position 4
actuator to be rotated by 90° in 4 different rotate insert bush 180° around rotate insert bush 180° around rotate insert bush 180° around
positions according to figure 4D. vertical-standard position (1) axis a-a, from position 2 axis a-a, from position 1
Insert bush turned upside down
5
bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
2.4.2 assembly procedure 2.5 pnEumatIc connEctIonS
Important Important
Failure to comply with the following procedures Check that the values of pneumatic supply
may impair product warranty. available are compatible with those reported on
the identification plate of the actuator.
WarnInG
Installation, commissioning and maintenance and WarnInG
repair works should be carried out by qualified The connections should be made by qualified
staff. A non-conforming assembly could be the staff. Use pipes and connections appropriate as
source of serious accidents. for type, material and dimensions. fIGurE 5 - Junction box on control group
(if foreseen).
For actuator assembly on the valve: • Properly de-burr the ends of rigid pipes.
• Properly clean the interior of pipes sending
Important through them plenty of the supply fluid used upon actuator commissioning please carry out
Check that the assembly position, as shown in the system. the following checks:
on the documentation, complies with system’s • Mould and fasten the connection pipes so that • Check that paint is not be damaged during
geometry. Check the consistency of the parts of no irregular strains at entries or loosening of transport, if necessary repair the damages to
actuator-valve coupling. threaded connections occur. paint coat.
• Make the connections according to the • Check that the pressure and quality of the
• Operate the actuator so that it reaches the operating diagram. gas supply (filtering degree, dehydration) are
position matching valve position (par. 3.3). • Check the absence of leakages from as prescribed. Check that the feed voltage
• Lubricate valve stem with oil or grease. pneumatic connections. values of the electric components (solenoid
• Properly clean and remove grease from valve coils, microswitches, pressure switches,
coupling flange surfaces. 2.6 ELEctrIcaL connEctIonS (If any) etc.) are compatible with those reported
• Connect, if supplied separately, the on the identification plate of the actuator
adjustment insert to valve stem and fasten it Important (figure 1).
with the special fastening pins. Use components appropriate as for type, material • Check that the setting of the components of
• Lift the actuator using the special lifting and dimensions. the actuator control unit (pressure regulator,
points (par. 2.2). pressure switches, flow control valves, etc.)
• Install the actuator so that valve stem inserts WarnInG meet the plant requirements.
in the coupling area. This coupling should be The connections should be made by qualified staff. • Carry out all kinds of operations and check
made without forcing. Before carrying out any operation, cut line their proper execution (par. 3.3).
• Fasten the two parts with the threaded power off. • Check the absence of leakages in the
connections (screws, tie rods, nuts). if Safety provisions: pneumatic connections. if necessary tighten
holes of coupling flanges are not aligned, 2006/95/EC: Directive for low voltage equipment. the nuts of the pipe-fittings.
adequately operate the actuator if necessary 2004/108/EC: Directive for the electromagnetic • Check proper operation of all the due
move the mechanical stops backwards compatibility. signalling (valve position, gas supply pressure
(par. 3.3). 94/9/CE: Directive and safety instructions for use etc.).
• Fasten threaded connections. Please refer to in hazardous area • Make a complete functional test in order
table 1. to verify all the operations are executed
remove plastic plugs from cables entries. according to operating schematic diagram
The screwing values in table 1 were calculated • Screw firmly the cable glands. supplied.
considering the materials asTM a320 l7 for • Introduce connection cables.
screws or tie rods and asTM a194 gr.2H for • Make the connections in compliance
the nuts. with applicable wiring diagrams on the
documentation supplied.
• Screw the cable gland.
• Replace the plastic plugs of unused entries
tabLE 1 - nutS tIGhtEnInG torquE with metal plugs.
threading tightening torque (nm)
M8 20 2.7 commISSIonInG
M10 40
M12 70 WarnInG
M14 110 Check that values of electrical supply to the
M16 160 control group (if foreseen) are compatible with
M20 320 those on the plate on the junction box (figure 5).
M22 420 Installation, commissioning and maintenance and
M24 550 repair works should be made by qualified staff.
M27 800
M30 1100
M33 1400
M36 1700
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bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
3. OperaTiOn anD use
For local or remote operations, please refer
for information only to par. 3.3 and prior
3.1 opEratIon DEScrIptIon to technical documentation furnished with
actuators.
in the normal operating situation, the alGa Typical schematics for various applications
actuator is fed by pressurized gas which flows are follow attached for information only, the
into the relevant cylinder chamber (for example function described are furnished only on
opening). The cylinder piston stroke causes specific customer demand.
the actuator operation and the consequent For all the relevant information please refer to the
valve movement to the operational position specific technical documentation supplied with
requested (in this case to the 'open' position). actuators.
upon a demand, the closing chamber the pneumatic connection
cylinder is fed by pressurized gas and at the
same time the gas is discharged from the open
chamber into the return line: the actuator fIGurE 6
performs the closing operation driven by the
piston movement, and the valve moves from
the open position to the close (safety-related)
position.
partS LISt
Item name
1 Housing
2 Yoke
3 Yoke bushing
4 Cover
5 Guide block pin
6 sliding block
7 Guide block
8 Guide bar
9 Guide block bushing
10 Travel stop screw
11 Cylinder head flange
12 piston rod bushing
13 piston rod seal
14 piston rod
15 piston
16 piston guide sliding ring
17 piston seal ring
18 Cylinder tube
19 end flange
20 Travel stop screw
21 sealing washer
22 Tie rod
fIGurE 7
7
bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
The diagram shows the simplest On-Off fIGurE 8a
control. The gas supply pressure is applied to On-OFF serViCe: FOur waY COnTrOl ValVe
one side of the cylinder and exhausted from
the opposite side. when the control valve (2) is
actuated the connection of supply and exhaust
to the cylinder chambers are reversed. The
control valve can have many types of actuating
devices (solenoid, manual control, pneumatic
pilot, spring, etc.). The spring return control
Manual control
valves allow 'fail safe' operation.
solenoid pneumatic pilot control
pressurized air control
atmospheric pressure air
Dual solenoid control
The system allows 'fail safe' operation when fIGurE 8b
the pressure in the gas supply line drops below On-OFF serViCe: air Fail saFe sYsTeM
a set value. The diagram shows the actuator in
the 'fail safe' condition. when the gas supply
pressure drops below the pressure switch (5)
set point, the pneumatic supply to the solenoid
valve (6) pilot is exhausted and the actuator
moves to the 'fail safe' position by using the gas
stored in the tank (4).The tank is connected to
the gas supply through the check valve (3).
pressurized air
pressurized air (low pressure)
atmospheric pressure air
when modulating control is required as a fIGurE 8c
function of a pneumatic or electric control MODulaTinG serViCe
signal, a positioned (5) is used, which controls
the supply to the actuator cylinder to keep
the valve in the required angular position. The
positioner has a mechanical linkage to the
actuator, for a feedback of the valve position.
electropneumatic
positioner
pneumatic pneumatic electric
positioner control signal control signal
pressurized air (suppy)
reduced pressurized air (opening chamber)
reduced pressurized air (closing chamber)
8
bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
The MHw - MsJ jackscrew manual override fIGurE 9a
can be supplied for model up to 3. The override eMerGenCenCY Manual OVerriDe
is mounted on the left side of the actuator, the
jackscrew end is screwed into the guide block.
a bronze split screw nut is mounted inside the
body. By rotating the engagement lever, the
screw nut is engaged with the jackscrew. when
the screw nut is engaged with the jackscrew
manual operation follows by rotating the body
of the screw container by a lever (for MsJ
models) or by a handwheel (for MHw models).
The MHp hydraulic manual override is used fIGurE 9b
to manually operate the actuator in lack of air MHp HYDrauliC Manual OVerriDe
supply. it also allows to accurately adjust the
actuator operating times, independently in
opening and in closing, by way of the hydraulic
regulators which work on the oil flow from
one chamber to the other of the hydraulic
cylinder during pneumatic operation. Moreover
it permits a smooth angular speed all along
the stroke. During manual operation the flow
regulators are by-passed to make the force
on the hand pump lever easy. The MHp unit
consists of a hydraulic cylinder mounted
directly on the actuator. The piston rod end
is screwed into the guide block. The compact
hydraulic control unit consists of a hand pump,
directional control valve, oil tank, relief valve
and two unidirectional flow regulators. The
directional control valve has three operating
positions: 'remote': the actuator is operated
by pneumatic supply; 'to open': the actuator
operation is opening by hand pump. On
request the hydraulic manual override type
MHp2 (double hand pump version) can be
supplied, which allows the remote control to
automatically override manual operation.
9
bIffI alGa DOuBle aCTinG pneuMaTiC aCTuaTOr
InstallatIon, operatIon and MaIntenance Manual
fIGurE 10a - pnEumatIc opEratIon fIGurE 10b - manuaL opEratIon
The diagram is drawn with actuator under pneumatic operation in opening. The diagram is drawn with actuator under manual operation towards open.
The flow regulator Fa allows control of the stroke time. The operation to be performed is selected by the directional control valve D.
pneumatic pneumatic
connection connection
to open to open
pneumatic pneumatic
connection connection
to close to close
scotch yoke mechanism ra = relief valve for automatic operation
pneumatic cylinde rm = relief valve for manual operation
Hydraulic cylinder p = Hand pump
Hydraulic manual override D = Hand operated directional control valve
High pressure oil Fa = unidirectional flow regulator (opening operation)
intermediate pressure oil Fc = unidirectional flow regulator (closing operation)
low pressure oil Fr = Bidirectional flow regulator
pressurized air C v = Check valve
atmospheric pressure air Ot = Oil tank
ls = level stick with relief valve
3.2 rESIDuaL rISkS
WarnInG
It is recommended to pipe exhaust gas.
The actuator has parts under pressure.
Use the due caution. Use individual protections
provided for by the laws and provisions in force.
3.3 caLIbratIon of thE anGuLar StrokE
11a
The angular stroke of the yoke can be adjusted
between 82˚÷98˚ (±4˚ with respect to the fIGurE 11a, 11b - Mechanical stops
nominal positions of complete opening and
closing) by means the mechanical stops
screwed into the left side of the housing (open
11b
valve) and into the end flange of the pneumatic
cylinder (closing) (figures 11a and 11B).
in case of an actuator with two cylinders
(figure 12), both mechanical stops are screwed
on the end flanges of the cylinders.
fIGurE 12 - actuator with two cylinders
10