BIFFI GIG User manual

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

December 2020

Bif GIG

Double-Acting Direct Gas Actuator

Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – bif_italia@bif.it

Revision Details

December 2020

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

Revision Details

Revision Date Description Prepared Checked Approved

7 December 2020 Migration to new template

6 April 2018 Updated Data-plate Ermanni Oreci Vigliano

5April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Oreci Vigliano

4 August 2015 Updated chapters 3.3.3 and 3.3.4 Ermanni Oreci Vigliano

3February 2013 Updated chapter 5.1.1 Ermanni Oreci Vigliano

2 July 2012 General update Ermanni Stoto Vigliano

1March 2009 General update Ermanni Stoto Vigliano

0May 1999 Document release Lazzarini Aliani Ziveri

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

Table of Contents

December 2020

Table of Contents

Section 1: General Warnings

1.1 Generalities................................................................................................... 1

1.1.1 Applicable Regulation ........................................................................ 1

1.1.2 Terms and Conditions......................................................................... 2

1.2 Identication Plate ........................................................................................ 2

1.3 Introducing the Actuator............................................................................... 3

1.4 Data Sheet .................................................................................................... 3

Section 2: Installation

2.1 Checks upon Actuator Receipt ...................................................................... 4

2.2 Actuator Handling......................................................................................... 4

2.3 Storage ......................................................................................................... 6

2.4 Actuator Assembly on the Valve.................................................................... 7

2.4.1 Types of Assembly.............................................................................. 7

2.4.2 Assembly Procedure......................................................................... 12

2.5 Pneumatic Connections .............................................................................. 13

2.6 Electrical Connections (If Any)..................................................................... 14

2.7 Commissioning........................................................................................... 15

Section 3: Operation and Use

3.1 Operation Description................................................................................. 16

3.2 Residual Risks.............................................................................................. 20

3.3 Operations.................................................................................................. 20

3.3.1 Local Pneumatic Operation .............................................................. 20

3.3.2 Electric Remote Control to Open and to Close .................................. 21

3.3.3 Emergency Manual Operation by MSJ / MHW ................................... 21

3.3.4 Emergency Manual Operation by MHP ............................................. 23

3.4 Calibration of the Angular Stroke ................................................................ 26

3.5 Calibration of Micro-switches (If Foreseen).................................................. 31

3.6 Calibration of the Operation Time............................................................... 32

Table of Contents

December 2020

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

Section 4: Operational Tests and Inspections

Operational Tests and Inspections..........................................................................34

Section 5: Maintenance

5.1 Periodic Maintenance.................................................................................. 35

5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override .......... 36

5.2 Extraordinary Maintenance ......................................................................... 39

5.2.1 Replacement of Cylinder Seals .......................................................... 39

5.3 Dismantling and Demolition ....................................................................... 43

5.4 Lubrication of Mechanism........................................................................... 44

Section 6: Troubleshooting

6.1 Failure or Breakdown Research.................................................................... 45

Section 7: Layouts

7.1 Spare Parts Order........................................................................................ 46

7.2 Parts List for Maintenance and Replacing Procedure.................................... 47

Section 8: Date Report for Maintenance Operations

Date Report for Maintenance Operations...............................................................54

Table of Contents

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7 December 2020

General Warnings 1

Section 1: General Warnings

NOTICE

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

Bif Italia s.r.l. actuators are conceived, manufactured and controlled according to the Quality

Control System in compliance with EN ISO 9001 international regulation.

1.1.1 Applicable Regulation

EN ISO 12100:2010: Safety of machinery – General principles for design –

Risk assessment and risk reduction

2006/42/EC: Machine directive

2014/68/EU: Directive for pressure PED equipment

2014/35/EU: Directive for low voltage equipment

2014/30/EU: Directive for the electromagnetic compatibility

2014/34/EU: Directive and safety instructions for use in hazardous area

NOTICE

Bif Italia s.r.l. pays the highest attention to collecting and verifying the documentation

contained in this user manual. However Bif 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 Bif Italia s.r.l. and may be

December 2020

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

General Warnings2

Section 1: General Warnings

1.1.2 Terms and Conditions

Bif Italia s.r.l. guarantees that all the items produced are free of defects in workmanship

and manufacturing materials and meet relevant current specications, 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 rst. All detailed warranty conditions are specied 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 modied 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 Bif Italia s.r.l. liability shall lapse in the event that any modication

or tampering whatsoever be performed on the actuator.

1.2 Identication Plate

! WARNING

It is forbidden to modify the information and the marks without previous written

authorization by Bif Italia s.r.l.

The plate fastened on the actuator contains the following information (Figure1).

Figure 1 Data plate

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7 December 2020

General Warnings 3

Section 1: General Warnings

1.3 Introducing the Actuator

The direct gas actuator GIG was engineered and is manufactured to provide fail safe

operation for any quarter turn application such as ball, plug, buttery valves or dampers,

in both ON-OFF and Modulating heavy duty service.

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

transforming the linear movement of the pneumatic cylinder (on closing or opening) into

the rotary movement, which is necessary for operation. The angular stroke of the yoke is

adjustable between 82° and 98° by means of the external mechanical stops screwed into

the left wall of the mechanism housing and into the end ange of the pneumatic cylinder.

The cover of the scotch yoke mechanism is arranged for the assembly of the required

accessories (positioner, signalling limit switches, position transducer, etc.) by means of

proper matching units. The above mentioned accessories are operated by the actuator

drive sleeve. The housing of the scotch yoke mechanism has a ange with threaded holes

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

adaptor ange or a mounting bracket. The actuator yoke has a hole with keyways suitable

for the assembly of an insert bush the internal hole of which is machined (by Bif or at

Customer's care), according to the shape and dimensions of the valve stem. Bif can supply

different types of control system following Customer's requirements.

The expected lifetime of actuator is approximately 25 years .

Supply uid Sweet, dry natural gas; sour high pressure gas; nitrogen or

instrument air

Operating temperature Standard: from –30 °C to +100 °C

Optional: from –60 °C to +140 °C

Supply pressure Please refer to technical document: “actuator data-sheet”

Figure 2 Identication of actuator parts

Manual handpump

MHP (optional)

Pneumatic cylinder

Valve position indicator

Valve Coupling

Scotch yoke

mechanism

1.4 Data Sheet

Hydraulic Cylinder

for GIG-MHP models or

second pneumatic cylinder

for “twin gas cylinder”

models (optional)

December 2020

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

Installation

Section 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 identication plate correspond with those of order conrmation,

see Section 1.2.

• Check that the actuator is equipped with the ttings as provided for by

order conrmation.

• Check that the actuator was not damaged during transportation: if necessary,

renovate the painting according to the specication reported on the

order conrmation.

• 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

micro-switches (if any) (Section 3.5).

2.2 Actuator Handling

NOTICE

The lifting and handling of the actuator must be done by qualied personnel and in

accordance with the laws and regulations in force. Avoid the lifted actuator to be hung

above the personnel.

! WARNING

The actuator must be lifted by means of a suitable lifting apparatus. The weight of the

actuators is indicated in the technical documentation attached to the equipment itself.

For lifting and moving the actuator, use only hooks tted with safety latch, like the one,

for example, shown in Figure 3.

Figure 3 Example of hook with safety latch

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7 December 2020

Installation 5

Section 2: Installation

Figure 4 Lifting points for GIG / GIG-MHP / GIG-MSJ / GIG-MHW actuators

1-2 = Lifting points (obligatory)

3= Balancing point

! WARNING

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

(manual handpump, manual jackscrew, pneumatic control group etc.).

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

adjustable length.

• Check each time the conditions of all lifting equipment used and discard it if

not in perfect working order.

• Do not knot or twist the ropes so as not to reduce the lifting capacity or

produce torsional effects on the load being lifted.

• Use the utmost caution and remain at a safe distance from lifted actuator

unless absolutely necessary; do not stand or pass under suspended loads.

• Pay attention in putting under tension the ropes to prevent the load shifting

sideways in an uncontrolled manner.

• Use slings of such length that the angles of the leg from vertical are as narrow

as possible (αMAX < 20°).

• During handling, do not transport the suspended actuator above staff

members in charge of the operation.

! WARNING

Do not use the lifting eyelets on actuator to lift valve + actuator assembly.

1= point of support

2= supports for lateral positioning

December 2020

Installation, Operation and Maintenance Manual

MAN 601 Rev. 7

Installation

Section 2: Installation

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).

Figure 5

LIFTING LUGS TO BE USED FOR THE

ACTUATOR ONLY. DO NOT LIFT VALVE

AND ACTUATOR TOGETHER

DO NOT DISASSEMBLE TOP OR

BOTTOM COVER.

SPRING LOADED.

POTENTIAL ELECTROSTATIC CHARGE HAZARD

BIFFI IS NOT LIABLE FOR ANY

PERSONNEL INJURY DUE TO

INCORRECT USE

REFER TO IOM

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