BIFFI RPS Installation, Operation And Maintenance Manual

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Before installation these instructions must be fully read and understood

1.1.1 Applicable regulation

EN ISO 12100-1: 2005: Safety of machinery Basic notions, general design principles. Part 1 - Basic terminology, method. 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 equipment

(PED).

2006/95/EC: Directive for low voltage

equipment.

2004/108/EC: Directive for the electromagnetic

TABLE OF CONTENTS

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

2. Installation ..................................................... 4

3. Operation and use ......................................... 8

4. Operational tests and inspections.............. 11

5. Maintenance. ............................................... 11

6. Troubleshooting .......................................... 16

7. Layouts ......................................................... 16

8. Date report for maintenance operations ... 21

1 GENERAL WARNINGS

IMPORTANT

The manual is an integral part of the machine.It should be read carefully before carrying out any operation and should be kept for future reference.

1.1 Generalities

Biffi actuators are conceived, manufactured and controlled according to the Quality Control System in compliance with EN ISO 9001 international regulation.

94/9/EC: Directive and safety instructions

1.1.2 Terms and conditions

Biffi 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.

compatibility.

for use in hazardous area.

VCIOM-03749-EN 17/12

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FIGURE 1 Data plate

1.2 Identification plate

It is forbidden to modify the information and the marks without previous written authorization by Biffi. The plate fastened on the actuator contains the following information (figure 1).

1.3 Introducing the actuator

RPS actuators are pneumatic low-pressure spring return, 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 is made up of a rack and pinion mechanism, which transforms the linear movement of the pneumatic cylinder, in one direction, and of the spring, in the opposite direction, into the rotary movement for the valve operation. An adjustable bronze sliding block supports the transverse force exerted on the rack by its engagement with the pinion. The rack is nitride for ensure the minimal friction. The spring module incorporates one or two springs in series, depending on the model, and is fully encapsulated. This assures safety to personnel and ease of assembly. 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 mounting flange is identical on both (upperand lower) faces of the housing; the shaft output drives have the same dimensions but is positioned at 90°. This allows the actuator to be used as spring to close or spring to open without modification. 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.

Actuator manual emergency operation in opposition to the spring action, is performed by rotating the jackscrew by a wrench or by a handwheel (available on request). The mounting flange, on the housing top, can be utilized 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 back face (optional), with threaded holes for the assembly of accessories (control panels, air storage tank, etc.).

The expected lifetime of actuator is approximately 30 years.

1.4 Technical data

Supply fluid Air, nitrogen or sweet gas Operating temperature Design pressure 12 bar maximum Supply pressure Please refer to technical data

Output torque Up to 3700 Nm

Standard: from -30°C to +100°C Optional: from -60° to +140°C

sheet

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FIGURE 2

Front side

№4 threaded holes

Top view

Back side

(The holes on the back side are optional)

ØE

K L

ØE

№4 threaded holes

DIMENSIONS (mm)

Actuator model A ± 0.2 B ± 0.2 C D ØE F G H K L ØM ± 0.2

RP 15 55 110 12.5 43 M8 14 17 98 114 67 181 RP 30 70 125 15.0 56 M10 16 35 120 136 80 216 RP 60 88 160 16.0 68 M12 19 35 150 160 105 265 RP 120 124 190 18.0 82 M16 23 50 183 210 124 334

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2 INSTALLATION

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 (section 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 (section 3.4) and of microswitches (if any) (section 3.5).

2.2 Actuator handling A. Valve stem with vertical axis

IMPORTANT

The lifting and handling should be made by qualified staff and in compliance with the laws and provisions in force.

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.

For a correct lifting procedure, please refer to figure 3A, 3B.

A. Valve stem with horizontal axis

The actuator can also be lifted to assemble directly onto the valve with stem with horizontal axis. To make this operation easier, Biffi suggest to move the lifting eyelet from its standard position, and place it in the suggested position, see figure 4.

FIGURE 3A, 3B Lifting points for RPS actuators

1, 2 = Lifting eyelets

1 = Points of support 2 = Do not lay the actuator on tie-rods

WARNING

Do not lay the actuator on accessories (manual hand pump, manual jackscrew, pneumatic control system etc.)

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FRONT VIEW SIDE VIEW

Lifting eyelets (standard position)

Lifting eyelets suitable for vertical stem

valve mounting position (standard)

TOP VIEW

BACK SIDE VIEW

Lifting point to balance weight (suitable for slings) (horizontal stem valve mounting position)

Lifting eyelets (horizontal stem valve mounting position)

FIGURE 4 A = Lifting eyelets B = Lifting point (balancing)

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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 (section 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 (see figure 5). 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).

FIGURE 5

№4 threaded holes №4 threaded holes

View from X View from Y

ØF

ØC ØC

ØE

IMPORTANT

To fix the actuator to the valve flange must be

ØH

Threaded hole ØN

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

ØM

Threaded hole ØN

COUPLING DIMENSIONS (mm)

Actuator model A ± 0.2 B ± 0.2 ØC D ØE ØF G ØH K J L ØM ØN

RP 14/15 49.5 49.5 M8 10 16 21 23 66 30 3 140 40 M5 RP 30 72.1 72.1 M10 12 22 29 25 92 32 3 164 50 M5 RP 60 88.4 88.4 M12 15 28 37 34 112 42 3 204 60 M5 RP 120 99.0 99.0 M16 23 37 49 45 132 55 3 270 75 M8

NOTE

Both the actuator flanges can be used for the coupling to the valve or the mounting of ancillary equipments (positoner, limit switch box, etc. )

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2.4.2 Assembly procedure

IMPORTANT

Failure to comply with the following procedures may impair product warranty.

WARNING

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:

IMPORTANT

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 (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 connections (screws, tie rods, nuts). If holes of coupling flanges are not aligned, adequately operate the actuator if necessary move the mechanical stops backwards (section 3.4).

• Fasten threaded connections. Please refer to table 1.

The screwing values in table 1 were calculated considering the materials ASTM A320 grade L7 for screws or tie rods and ASTM A194 grade 2H for the nuts.

2.5 Pneumatic connections

Connect the actuator to the pneumatic feed line with fittings and pipes in accordance to the plant specifications. They must be sized correctly in order to guarantee the necessary air flow for the operation of the actuator, with pressure drops not exceeding the maximum allowable value. The shape of the connecting piping must

TABLE 1 - NUTS TIGHTENING TORQUE

Threading Tightening torque (Nm)

M8 20 M10 40 M12 70 M16 160

not cause excessive stress to the inlets of the actuator. The piping must be suitably fastened so as not to cause excessive stress or loosening of threaded connections, if the system undergoes strong vibrations. Every precaution must be taken to ensure that any solid or liquid contaminants which may be present in the pneumatic pipe-work to the actuator are removed to 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 air or nitrogen. The ends of the tubes must be well deburred and cleaned. Once the connections are completed, operate the actuator and check that it functions correctly, that the operation times meet the plant requirements and that there are no leakages in the pneumatic connections.

2.6 Electrical connections (if any)

WARNING

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).

Connect the electrical feed, control and signal lines to the actuator, by linking them up with the terminal blocks of the electrical components. In order to do this, the housing covers must be removed without damaging the coupling surfaces, the O-rings or the gaskets. Remove the plugs from the cable entries. For electrical connections use components (cable glands, cables, hoses, conduits) which meet the requirements and codes applicable to the plant specifications (mechanical protection and/or explosion-proof protection). Screw the cable glands tightly into the threaded inlets, so as to guarantee the weatherproof and explosionproof protection (when applicable). Insert the connection cables into the electrical enclosures through the cable glands, and connect the cable wires to the terminals according to the applicable wiring diagram. If conduits are used, it is advisable to carry out the connection to the electrical enclosures by inserting hoses so as not to cause anomalous stress on the housing cable entries. Replace the plastic plugs of the unused enclosure entries by metal ones, to guarantee perfect weatherproof tightness and to comply with the explosion-proof protection codes (where applicable).Once the connections are completed, check that the controls and signals work properly.

2.7 Commissioning

WARNING

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, except the angular stroke setting because for this setting operation, the actuator must be placed on to the valve (see section 3.4). Before any modifications please contact Biffi.

Upon actuator commissioning please carry out the following checks:

• Check that the pressure and quality of the air supply (filtering degree, dehydration) are as prescribed. Check that the feed voltage values of the electrical components (solenoid valve coils, microswitches, pressure switches, etc.) are as prescribed.

• Check that the actuator controls work properly (remote control, local control, emergency controls, etc.).

• Check that the required remote signals (valve position, air pressure, etc.) are correct.

• 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 there are no leakages in the pneumatic connections. If necessary tighten the nuts of the pipe fittings.

• Remove all rust and, in accordance with the applicable painting specifications, repair paint-coat that has been damaged during transport, storage or assembly.

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3 OPERATION AND USE

3.1 Operation description

The air pressurizes the cylinder chamber and 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, in one direction. The operation in the opposite direction is made by the linear movement generated from the spring releasing, when the opposition of pneumatic supply is discharged from the cylinder. For local or remote operations related to the actuator, please refer to technical documentation furnished with delivery actuators (schematics, overall dimensions and parts list).

IMPORTANT

Typical general schematics for various applications are follow attached for information only, various control systems are furnished only at customer demand:

Manual override for RPS spring return pneumatic actuator

Actuator manual emergency operation in opposition to the spring action, is performed by rotating the jackscrew by a wrench or by a handwheel (available on request).

FIGURE 7

FIGURE 6

Pneumatic connection

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FIGURE 8A

Pressurized air Atmospheric pressure air

FIGURE 8B

On-Off service: three way control valve

The diagram shows the simplest On-Off

control. The control valve (2) has two positions. In one position the gas supply pressure is connected to the cylinder chamber, and the actuator performs the “pneumatic” operation. In the other position the cylinder is connected to the exhaust and the actuator moves under the operation of the spring. The control valve can have many types of actuating devices (solenoid, manual control, pneumatic pilot, spring, etc.).

Solenoid

control

Manual control

Pneumatic pilot control

The spring return control valves allow “failsafe” operation.

On-Off service: quick spring operation

When fast action is required under spring operation, a quick exhaust valve (3) is installed in the cylinder directly port to exhaust the gas from the cylinder directly to the atmosphere.

When the control valve (2) opens to the atmosphere a differential pressure is created across the quick exhaust valve (3) causing it

to open. The resultant high flow capacity from cylinder to atmosphere allows quick spring operation of the actuator.

Pressurized air Atmospheric pressure air

FIGURE 8C

Pneumatic

Pressurized air (supply) Reduced pressure air

positioner

Pneumatic

control signal

Electropneumatic

positioner

Electric

controlsignal

Modulating service

When modulating control is required as a function of a pneumatic or electric control signal, a positioner (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.

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3.2 Residual risks

WARNING

The actuator has parts under pressure. 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

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 angular stroke is performed by adjusting the travel stop screws of the cylinder end flange and of the housing wall. The setting of the open valve position is performed by adjusting the travel stop screw on the left side of the actuator (screwed in the housing wall for spring to close actuators or in the cylinder end flange for spring to open actuators). The setting of the closed valve position is performed by adjusting the travel stop screw on the right side of the actuator (screwed in the cylinder end flange for spring to close actuators or in the housing wall for spring to open actuators). For the adjustment of the travel stop screws proceed as follows (see figures 9A, 9B):

1. Loosen the lock nut with wrench C2.

2. If the actuator angular stroke is stopped before reaching the end position (fully open or closed), unscrew with wrench C1 the travel stop screw by turning it anticlockwise, until the valve reaches the right position. When unscrewing the travel stop screw, keep the lock nut still with a wrench so that the sealing washer does not withdraw together with the travel stop screw.

3. Tighten the lock nut (refer to torque table to avoid accidental unscrewing of the lock nut).

4. 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 right position.

5. Tighten the lock nut (refer to torque table to avoid accidental unscrewing of the lock nut).

Wrench C2

Actuator model Thread

RP 14/15 M30x2 41 150 RP 30 M40x2 50 350 RP 60 M45x2 55 500 RP 120 M50x2 60 800

(mm)

Torque

FIGURE 9A, 9B

Wrench C1

Actuator model

RP 14/15 17 41 RP 30 17 50 RP 60 17 55 RP 120 17 60

(mm)

Wrench C2

(mm)

Without jackscrew manual override

Wrench C1

Actuator model

RP 15-MSJ/MHW 24 41 RP 30-MSJ/MHW 32 50 RP 60-MSJ/MHW 36 55 RP 120-MSJ/MHW 36 60

(mm)

Wrench C2

(mm)

With jackscrew manual override MSJ or handwheel manual override MHW

(Nm)

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3.5 Calibration of the operating time

(optional- if foreseen)

The calibration of the operating time is made according to customer requirements and to technical data sheet included in technical documentation. If necessary it’s possible to modify or reset the operating time through the flow regulator valve placed on inlet of pneumatic supply (figure 19).

4 OPERATIONAL TESTS AND INSPECTIONS

IMPORTANT

To ensure the guaranteed SIL Level, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described following.

For safety related applications, the following test operation has to be performed:

1. Full stroke of actuator once a year.

2. Partial stroking test at least every six months (if applicable, please refer to operating diagram and operate accordingly).

3. Visual inspection-checks , according to section 5.1, but with a frequency of once a year.

For standard applications please refer to section 5.1.

5 MAINTENANCE

IMPORTANT

Before executing any maintenance operation, it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator and from the control unit (if foreseen).

WARNING

Installation, commissioning and maintenance and repair works should be carried out by qualified staff.

5.1 Periodic maintenance

RPS actuators are designed to operate longterm in heavy-duty operating conditions, without maintenance needs.

IMPORTANT

Periodicity and regularity of inspections is particularly influenced by specific environmental and working conditions. They can be initially determined experimentally and then be improved according to actual maintenance conditions and needs.

FIGURE19 Example of operating time adjustment by flowregulator valve (please refer to specific operating diagram)

Pneumatic connection

(close) screw for decrease speed

Wrench

Screwdriver

(open) unscrew for increase speed of operation

Anyway every 2 years of operation the following is recommended:

• Check that the 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 all the paint-coat of the actuator. If some areas are damaged, repair the paint-coat according to the applicable specification.

• Check there are no pneumatic leakages If necessary tighten the nuts of the pipe-fittings.

• Check the integrity of worn out parts (gaskets, pads etc.).

• If there is an air filter on the actuator, bleed the condense water accumulated in the cup by opening the drain cock. Disassemble the cup periodically and wash it with soap and water; disassemble the filter: if this is made up of a sintered cartridge, wash it with nitrate solvent and blow through with air. If the filter is made of cellulose, it must be replaced when clogged.

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5.2 Extraordinary maintenance

If there are leaks in the pneumatic cylinder or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembled and seals must be replaced with reference to the following general sectional drawing and adopting the following procedures.

5.2.1 Replacement of cylinder seals

(refertosectional drawing, figure 20)

IMPORTANT

Before carrying out any maintenance operation, it is necessary to close the pneumatic feed line and exhaust the pressure from the actuator and from the control unit, to ensure safety of maintenance staff. Installation, commissioning and maintenance and repair works should be carried out by qualified staff. Before carrying out any operation, cut power off from the electrical line.

Replacement of cylinder seals

1. Measure the protrusion of the stop screw (30) with reference to the end flange (4) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

2. Loosen the lock nut (10) and unscrew the stop screw (30) together with the nut (10), the washer (28) and the sealing washer (17).

3. Unscrew the nuts (25) from the tie rod (14) from the side of the end flange: they must be gradually unscrewed all at the same time.

4. Slide off the end flange (4) and the tube (13). The spacer tube (33) must remain in place. Take care not to damage the plane surfaces of the tube ends.

4. Carefully clean the ends of the cylinder tube (13) and of the spacer tube (33), which must fit together, to remove any trace of the sealant which assures tightness.

5. Remove the sealing washer (17) from the travel stop screw (30). Carefully clean and lubricate the travel stop screw thread and the surface of the end flange area, where the sealing washer is.

6. Screw the new sealing washer onto the travel stop until it is in contact with the nut (10).

7. Assemble the washer (28) onto the sealing washer (17).

Reassemble

1. Assemble the new cylinder gasket (7) on its seat on the end flange (4).

2. Carefully clean the inside of the tube (13) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate the inside surface of the tube and the bevels at the ends.

3. Spread some sealant LOCTITE 510, or equivalent, on the cylinder tube end (13), which is connected to the spacer tube (33).

4. Slide the cylinder tube (13) onto the piston taking care not to damage the piston O-ring (24).

5. Assemble the end flange (4) centring it on the tube (13). Assemble the nuts (25) onto the tie rod (14). Tighten the nuts to the recommended torque (see table), alternating between opposite corners. Screw the travel stop screw into the threaded hole of the end flange until it reaches its original position (the same protrusion with reference to the flange surface).

6. Check that the sealing washer (17) and the washer (28) are in contact with the end flange surface.

7. Tighten the lock nut (10).

Seals replacement

Prior to reassemble check that the actuator components are in good conditions and clean. Lubricate all the surfaces of the parts, which move in contact with other components, by recommended by recommended oil (SHELL Omala S4 WE 320 or equivalent). If the O-ring must be replaced, remove the existing one from its groove, clean the groove carefully and lubricate it with protective oil film. Assemble the new O-ring into its groove and lubricate it with a protective oil film.

1. Replace the O-ring (24) and the piston guide sliding ring (20).

2. Remove the existing gasket (7) from its seat in the end flange (4).

3. Carefully clean the seat of the gasket in the end flange (4) and the plane surface, of the tube end (13), which is in contact with the gasket (7).

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Replacement of mechanism seals

To replace the O-rings of the shaft (6) proceed as follows:

1. Remove the retainer ring (21).

2. Disassemble the shoulder washer (8). Remove the existing O-ring (23) from its groove. Clean the groove and the shaft carefully and lubricate it with protective oil film.

3. Assemble the new O-ring into its groove and lubricate it with protective oil or a grease film. Assemble the shoulder washer (8). Assemble the retainer ring (21).

If the sealing washer (17) has to be replaced, measure the protrusion of the stop screw (30) with reference to the housing (1) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.

1. Loosen the lock nut (10) and remove the stop screw (30) together with the nut (10), the washer (28) and the sealing washer (17). Remove the sealing washer (17) from the stop screw (30). Carefully clean and lubricate the stop screw thread and the surface on the housing area, where the sealing washer is.

2. Screw the new sealing washer onto the stop screw until it is in contact with the nut (10). Assemble the washer (28) onto the sealing washer (17).

3. Screw the stop screw into the threaded hole of the housing until it reaches its original position (the same protrusion with reference to the housing surface). Check that the sealing washer (17) and the washer (28) are in contact with the housing surface. Tighten the lock nut (10).

If the sealing washer (18) has to be replaced, measure the protrusion of the thrust bearing screw (15) with reference to the housing (1) surface, so as to be able to easily restore the setting of the position of the thrust bearing sliding block with reference to the rack once the maintenance procedures have been completed.

1. Loosen the lock nut (26) and remove the screw (15) together with the sliding block (19), the nut (26), the washer (27) and the sealing washer (18). Remove the sealing washer (18) from the screw (15). Carefully clean and lubricate the screw thread and the surface of the housing area, where the sealing washer is.

2. Screw the new sealing washer onto the screw until it is in contact with the nut (26).

3. Assemble the washer (27) onto the sealing washer (18).

4. Screw the thrust bearing screw (15), complete with the sliding block (19), into the threaded hole of the housing until it reaches its original position (the same protrusion with reference to the housing surface).

5. Check that the sealing washer (18) and the washer (27) are in contact with the housing surface. Tighten the lock nut (26).

IMPORTANT

AFTER MAINTENANCE OPERATIONS CARRY OUT A FEW ACTUATOR OPERATIONS TO CHECK THAT ITS MOVEMENT IS REGULAR AND THAT THERE IS NO AIR LEAKAGE THROUGH THE SEALS.

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FIGURE 20 RPS spring return pneumatic actuator

2230

*1313

1 2

PARTS LIST

Item Description

1 Housing 2 Pinion 3 Piston 4 End flange 5 Rack 6 Shaft 7 Cylinder gasket 8 Shoulder washer 10 Nut 11 Spring retainer disk 12 Rack spacer rod 13 Cylinder tube

Item Description Item Description

14 Tie rod 15 Thrust bearing screw 16 Spring 17 Sealing washer 18 Sealing washer 19 Sliding block 20 Piston guide sliding ring 21 Retainer ring 22 Screw 23 O-ring 24 O-ring 25 Nut

26 Nut 27 Washer 28 Washer 30 Travel stop screw 31 Screw 32 Plug 33 Spacer tube *1 Stop setting screw *2 Manual override jack screw *3 O-ring * applicable to RPS with handwheel manual override

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5.3 Lubrication of mechanism

For normal duty the rack-and-pinion 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 moving parts, especially on the surface of the rack in contact with the thrust bearing sliding block and on the teeth of the rack and pinion. For this operation proceed as follows:

1. Disassemble the actuator from the valve.

2. Measure the protrusion of the stop screw (30) with reference to the end flange surface (4), so as to be able to easily restore its setting once the maintenance procedures have been completed.

3. Loosen the lock nut and unscrew the stop screw until it is removed.

4. Remove the nuts (25) from the tie rod (14) at the end flange side: they must be gradually unscrewed all at the same time so as to release the thrust of the spring against the flange.

5. Slide off the end flange (4) and the cylinder tube (13).

6. Measure the protrusion of the thrustbearing screw (15), with reference to the housing surface, so as to be able to restore the right working position of the thrust bearing sliding block with reference to the rack once the maintenance procedures have been completed.

7. Remove from the actuator the complete spring module, the main components of which are the piston (3), the spring (16), the rack spacer rod (12), the spring retainer disk (11) and the rack (5).

8. Remove the spacer tube (33).

9. Lubricate abundantly the teeth of the rack and pinion and the surface of the rack in contact with the thrust bearing sliding block. Use recommended grease.

Prior to reassemble:

1. Check that the actuator components are in good conditions and clean.

2. Substitute the gaskets and the O-rings if worn or damaged.

3. Assemble all the components, taking care not to damage the seals.

The following grease is used by Biffi for standard working temperature and suggested for re-lubrication (see table).

AGIP MU/EP/2 AEROSHELL GREASE 7 or equivalent

To be used in standard temperature conditions (-30°C/+85°C)

NLGI consistency: 2 Worked penetration: 280 dmm ASTM dropping point: 185°C Base oil viscosity at 40°C: 160 mm²/s ISO classification: L-X-BCHB 2 DIN 51 825: KP2K - 20

Equivalent to: ESSO BEACON EP2 BP GREASE LTX2 SHELL ALVANIA GREASE R2 ARAL ARALUB HL2 CHEVRON DURALITH GREASE EP2 CHEVRON SPHEEROL AP2 TEXACO MULTIFAK EP2 MOBILPLEX 47 PETROMIN GREASE EP2

To be used in low temperature conditions (-60°C/+65°C)

Color: Buff Physical state: Semi-solid at ambient temperature Odor: Slight Density: 966 kg/m³ at 15°C Flash point: >215°C (COC)(based on synthetic oil) Dropping point: 260°C (ASTM D-566) Product code: 001A0065 Infosafe no.: ACISO GB/eng/C

5.4 Dismantling and demolition

WARNING

Before starting the disassembly a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by work-site.

Before disassembling the actuator it is necessary to close the pneumatic feed line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank, if present.

The opposition of pneumatic supply is discharged from the cylinder by the linear movement generated from the spring releasing. It moves actuator and consequently the valve, in hits fail safe position. 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 sect. 2.2). If the actuator needs storage, before demolition, see chapter 2.3

WARNING

The demolition of the actuator both concerning any electrical and mechanical parts should be made by specialized staff.

Separate the parts composing the actuator according to their nature (ex. metallic, and plastic materials, fluids etc.) and send them to differentiated waste collection sites, as provided for by the laws and provisions in force.

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

6 TROUBLESHOOTING

6.1 Failure or breakdown research

Event Possible cause Remedy

Actuator does not work 1. Lack of power supply 1. Restore it

2. Clogged filter 2. Clean or replace the cartridge

3. Blocked valve 3. Repair or replace

4. Failure of the spring 4. Call Biffi Customer Service

5. Failure of the control group 5. Call Biffi Customer Service

6. Low supply pressure 6. Restore (section 1.4)

Actuator too slow 1. Low supply pressure 1. Restore (section 1.4)

2. Wrong calibration of flow regulator valves 2. Restore (section 3.6)

3. Wear of the valve 3. Replace

Actuator too fast 1. High supply pressure 1. Restore (section 1.4)

2. Wrong calibration of flow regulator valves 2. Restore (section 3.6) Leakages on hydraulic circuits 1. Deterioration and/or damage to gaskets 1. Call Biffi Customer Service Incorrect position of the valve 1. Wrong adjustment of mechanical stops 1. Restore (section 3.4)

2. Wrong warning of microswitches 2. Restore (section 3.5) Irregular movement of actuator or lower torque value 1. Wrong adjustment or unscrewing of thrust bearing-screw 1. See figure 21 below

FIGURE 21

Restore the correct position of thrust bearing-screw

7 LAYOUTS

7.1 Spare parts order

For spare parts order to the relevant Biffi office please make reference to Biffi 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. Servizio Assistenza Tecnica Clienti E-mail: spareservice

@biffi.it

Please specify:

1. Actuator model

2. Biffi acknowledgement

3. Spare parts code

4. Quantity

5. Transport condition

6. Involved people

Please refer to figure 20 section 5.2.1: Screw the thrust bearing screw (15), complete with the sliding block (19), into the threaded hole of the housing until it reaches the correct original position. Check that the sealing washer (18) and the washer (27) are in contact with the housing surface. Tighten the lock nut (26).

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

7.2 Parts list for maintenance and replacing procedure

FIGURE 22 Rack and pinion mechanism RPS S2-A1/B1/C1 single acting pneumatic actuator

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

PARTS LIST - RPS S2-A1/B1/C1

Item Qty Description Material

1 1 Housing Nodular cast iron 2 1 Pinion Nodular cast iron 3 1 Piston Carbon steel 4 1 End flange Carbon steel 5 1 Rack Nodular cast iron 6 1 Shaft Alloy steel 7* 2 Cylinder gasket NBR 8* 2 Shoulder washer Nylon 9 2 Lifting eyelet Carbon steel 10 2 Nut Carbon steel 11 1 Spring retainer disk Carbon steel 12 1 Rack spacer rod Carbon steel 13 1 Cylinder tube Nickel plated carbon steel 14 4 Tie rod Alloy steel 15 1 Thrust bearing screw Alloy steel 16 1 Spring Alloy steel 17* 2 Sealing washer PVC 18* 1 Sealing washer PVC 19 1 Sliding block Bronze 20* 1 Piston guide sliding ring PTFE + graphite 21* 2 Retainer ring Spring steel 22 1 Screw Alloy steel 23* 2 O-ring NBR 24* 1 O-ring NBR 25 8 Nut Carbon steel 26 1 Nut Carbon steel 27 1 Washer Carbon steel 28 2 Washer Carbon steel 29 4 Spring pin Carbon steel 30 2 Travel stop screw Carbon steel 31 1 Screw Alloy steel 32 1 Plug Aluminium + bronze + steel 36 1 Spacer tube Carbon steel * Recommended spare parts

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

FIGURE 23 RPS 2.4 / RPS 3.1 single acting pneumatic actuator

26 18

10 28

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

PARTS LIST - RPS 2.4 / RPS 3.1

Item Qty Description Material

1 1 Housing Nodular cast iron 2 1 Pinion Nodular cast iron 3 1 Piston Carbon steel 4 1 End flange Carbon steel 5 1 Rack Nodular cast iron 6 1 Shaft Alloy steel 7* 2 Cylinder gasket NBR 8* 2 Shoulder washer Nylon 9 -- -- -10 2 Nut Carbon steel 11 1 Spring retainer disk Carbon steel 12 1 Rack spacer rod Carbon steel 13 1 Cylinder tube Nickel plated carbon steel 14 4 Tie rod Alloy steel 15 1 Thrust bearing screw Alloy steel 16 1 Spring Alloy steel 17* 2 Sealing washer PVC 18* 1 Sealing washer PVC 19 1 Sliding block Bronze 20* 1 Piston guide sliding ring PTFE + graphite 21* 2 Retainer ring Spring steel 22 1 Screw Alloy steel 23* 2 O-ring NBR 24* 1 O-ring NBR 25 8 Nut Carbon steel 26 1 Nut Carbon steel 27 1 Washer Carbon steel 28 2 Washer Carbon steel 29 4 Spring pin Carbon steel 30 2 Travel stop screw Carbon steel 31 1 Screw Alloy steel 32 1 Plug Aluminium + bronze + steel 33 -- -- -34 -- -- -35 -- -- -36 1 Spacer tube Carbon steel 37 1 Intermediate flange Carbon steel 38* 2 O-ring NBR 39 4 Tie rod Alloy steel 40* 1 O-ring NBR 41 4 Nut Carbon steel 43 1 Screw Carbon steel * Recommended spare parts

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RPS SPRING RETURN PNEUMATIC ACTUATOR

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

8 DATE REPORT FOR MAINTENANCE OPERATIONS

Last maintenance operation date:

(in factory, on delivery): ….....................................

....…...............… exec. by: …...............................……

Next maintenance operation date:

....…...............… exec. by: …...............................……

Start-up date:

(in factory, on delivery): .……………………................

(on plant): ….....................................

Biffi reserves the right to change product designs and specifications without notice.

Biffi Italia S.r.L.

Località Caselle San Pietro, 420, 29017 Fiorenzuola d'Arda (PC) ITALY Ph: +39 (0)523 944 411 E-mail: biffi_italia@biffi.it www.biffi.it