BIFFI PLAS Series Installation, Operation And Maintenance Manual
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BIFFI PLAS Series Installation, Operation And Maintenance Manual

Spring-return pneumatic linear actuator
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Biffi PLAS
Spring-Return Pneumatic Linear Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:
Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it
Installation, Operation and Maintenance Manual
MAN 617 Rev. 6
August 2020

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  • Page 1 Spring-Return Pneumatic Linear Actuator Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Revision Details Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Revision Details Rev. Date Description Prepared Checked Approved August 2020 Updated cover image June 2020 General update (Migration to new template) May 2018 Updated Data-plate Ermanni Orefici Vigliano April 2016 Updated applicable regulation (Section 1.1.1)

  • Page 3: Table Of Contents

    3.3.4 Emergency Manual Operation by MHP ..........17 Calibration of the Linear Stroke..............17 Calibration of Micro-Switches (for Biffi limit switch box*) ......20 Calibration of the Operation Time ............. 22 Section 4: Operational Tests and Inspections Operational Tests and Inspections ............24...
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Section 5: Maintenance Periodic Maintenance ................25 5.1.1 Check and Restore Oil Level In The Gas-Hydraulic Tanks ....26 5.1.2 Gas Supply Dehydrating Filter Maintenance (if foreseen) ....28 Extraordinary Maintenance ...............

  • Page 5: Section 1: General Warnings

    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.

  • Page 6: Terms And Conditions

    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.

  • Page 7: Introducing The Actuator

    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.

  • Page 8: Data Sheet

    Section 1: General Warnings Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Table 1. PLAS 250k 100k Manual override Spring action Stroke (mm) Spring ending thrust (N) Cylider diameter (mm) Max. allowable thrust (N) Spring-return actuator Data Sheet Supply fluid Air, Nitrogen or sweet gas Operating temperature...

  • Page 9: Section 2: Installation

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 617 Rev. 6 August 2020 Section 2: Installation 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, see Section 1.2.

  • Page 10: Storage

    Section 2: Installation Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 4 Positioning by Chains Point of support Don’t lay the actuator on tie-rods of cylinder. Don’t lay the actuator on accessories (manual handpump, manual jackscrew, pneumatic control system, etc.).

  • Page 11: Actuator Assembly On The Valve

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 617 Rev. 6 August 2020 Actuator Assembly on the Valve 2.4.1 Types of Assembly 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).
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 To assemble the actuator onto the valve by bracket with threaded joint proceed as follows: Figure 5 Pedestal with Threaded Coupling Joint Table 1. Parts List Item Description Stud bolt...
  • Page 13 Installation, Operation and Maintenance Manual Section 2: Installation MAN 617 Rev. 6 August 2020 Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions (valve stem and flange). Lubricate the valve stem with grease in order to make the assembly easier. Connect a sling to the support point of the actuator and lift it.
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 To assemble the actuator onto the valve by bracket with shell joint, perform the following operations: Figure 6 Pedestal with Shell Coupling Joint Table 2. Parts List Item Description Stud bolt...
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation MAN 617 Rev. 6 August 2020 Check that the coupling dimensions of the valve flange and stem, or of the relevant extension, meet the actuator coupling dimensions (valve stem and flange). Lubricate the valve stem with grease in order to make the assembly easier. To make easier the assembly, the valve stem has to be in perfect vertical position.

  • Page 16: Pneumatic Connections

    Section 2: Installation Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Pneumatic Connections WARNING Check that the values of pneumatic supply available are compatible with those reported on the identification plate of the actuator. NOTICE The connections should be made by qualified staff. Use pipes and connections appropriate as for type, material and dimensions.

  • Page 17: Commissioning

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 617 Rev. 6 August 2020 Commissioning WARNING Installation, commissioning and maintenance and repair works should be made by qualified staff. Upon actuator commissioning please carry out the following checks: • Check that paint is not be damaged during transport, if necessary repair the damages to paint coat.

  • Page 18: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Section 3: Operation and Use Operation Description The supply gas pressurizes the pneumatic cylinder chamber, this pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled. The valve is actuated in opening and in closing position by the actuator pneumatic cylinder in one direction and by the spring unit in the other direction.

  • Page 19: Residual Risks

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 617 Rev. 6 August 2020 Figure 9 Single-Acting (spring-return) actuator with jackscrew manual override type MHP Residual Risks WARNING It is recommended to pipe exhaust gas. The actuator has parts under pressure. Use the due caution.

  • Page 20: Electric Remote Control To Open And To Close

    Section 3: Operation and Use Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 10 PLAS MHP without control system Pressurize the pneumatic cylinder chamber, this pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled. The valve is actuated in opening and in closing position by the actuator pneumatic cylinder in one direction and by the spring unit in the other direction.

  • Page 21: Emergency Manual Operation By Mhp

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 617 Rev. 6 August 2020 3.3.4 Emergency Manual Operation by MHP (when sufficient line pressure is not available) • Select by the valve 5-D the opening or closing operation. •...
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 For the adjustment in PLAS with hydraulic manual override the mechanical stop is placed on the end flange of hydraulic cylinder, follow these steps (Figure 12): Remove with the specific wrench (c1) the plug (t).
  • Page 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 617 Rev. 6 August 2020 For the adjustment of the mechanical stop screwed on the end flange of manual override (see also Section 7.2, Table 15: sectional drawing for manual jackscrew MSJ) proceed as follows: Loosen the lock nut (item 2).

  • Page 24: Calibration Of Micro-Switches (For Biffi Limit Switch Box*)

    Section 3: Operation and Use Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Calibration of Micro-Switches (for Biffi limit switch box*) WARNING *If different micro-switches assembly or limit switch box is supplied, please refer to the specific documentation. NOTICE Operate only the micro-switch corresponding to the direction of operation being carried out, as clearly reported on the micro-switch.
  • Page 25 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 617 Rev. 6 August 2020 Figure 14 Micro-switches Box Figure 15 Cam Adjustment If the index (Figure 16), does not signal the proper position of the valve but is turned by 90°: •...

  • Page 26: Calibration Of The Operation Time

    MAN 617 Rev. 6 Calibration of the Operation Time The calibration of the operation time is made by Biffi Italia s.r.l. 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 regulation valve placed between the control valves enclosure and the pneumatic cylinder (Figure 17).
  • Page 27 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 617 Rev. 6 August 2020 For PLAS actuator models with Manual Handpump, the operating time is adjustable through two regulation valves placed on manual handpump body (see Section 7.2, Table 13: sectional drawing for hydraulic control unit MHP).

  • Page 28: Section 4: Operational Tests And Inspections

    Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Section 4: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual. Operational Tests and Inspections...

  • Page 29: Section 5: Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 617 Rev. 6 August 2020 Section 5: Maintenance NOTICE 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.

  • Page 30: Check And Restore Oil Level In The Gas-Hydraulic Tanks

    Section 5: Maintenance Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 19 Level measuring stick Maximum level Minimum level 5.1.1 Check and restore oil level in the hydraulic manual handpump Operate the distributor lever to “manual operation” to operate valve and to compress completely the actuator spring.
  • Page 31 MAN 617 Rev. 6 August 2020 NOTICE For refill use oil of the same brand as the one in the tanks. Table 5. Features of Hydraulic Oil Used by Biffi Italia s.r.l. Standard temperature conditions (-30 °C/+85 °C): Producer AGIP Name ARNICA 22 Viscosity at 40 °C...

  • Page 32: Gas Supply Dehydrating Filter Maintenance (If Foreseen)

    Section 5: Maintenance Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 5.1.2 Gas Supply Dehydrating Filter Maintenance (if foreseen) The gas supply filter is fitted with a mechanical filter and a drain valve to discharge periodically the water generated by the condensation of the humidity inside the gas supply. During the routine maintenance it is recommended to check and clean the mechanical filter and replace it in case of heavy dirty conditions.
  • Page 33 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 617 Rev. 6 August 2020 Figure 21 Stop setting screw cover Stop setting screw Plug WARNING Before disassembling the cylinder, make sure the above operation of spring release is done. For standard version, proceed as follow (see Figures in following pages): Unscrew the plug (36) from the adjusting screw cover (28).
  • Page 34 Section 5: Maintenance Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 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 grease (AGIP-ENI LCX 2/32 if seals are in NBR/Viton or Neoprene rubber, or with Aeroshell Grease 7 if the seals are in Fluorosilicon rubber).
  • Page 35 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 617 Rev. 6 August 2020 Figure 22 PLAS with threaded coupling joint Table 6. Parts list Item Description Item Description Cylinder tube Stud bolt Screw Support joint Screw Connecting joint Sealing washer Scraper support Piston Scraper ring...
  • Page 36 Section 5: Maintenance Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 23 PLAS with shell coupling joint Table 7. Parts list Item Description Item Description Stud bolt Cylinder tube Screw Screw Screw Connecting device Pedestal Piston Actuator joint End flange Stem valve joint...

  • Page 37: Dismantling And Demolition

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 617 Rev. 6 August 2020 Dismantling and Demolition WARNING Before disassembling the actuator it is necessary to close the pneumatic supply line and discharge pressure from the cylinder of the actuator, from the control unit and from the accumulator tank, if present.

  • Page 38: Section 6: Troubleshooting

    Repair or replace Actuator does Wrong position of the distributor Restore correct position not work of the hydraulic manual override Call Biffi Italia s.r.l. Failure of the control system Customer Service Low supply pressure Restore (Section 1.4) Low supply pressure Restore (Section 1.4)

  • Page 39: Section 7: Layouts

    Section 7: Layouts 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, refer to Section 1.2 for any specific spare part for a specific actuator model.

  • Page 40: Parts List For Maintenance And Replacing Procedure

    Section 7: Layouts Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Parts List for Maintenance and Replacing Procedure Figure 24 Pedestal with Coupling Joint Table 9. Parts List - Pedestal with Coupling Joint Item Description Material Pedestal Carbon steel Antirotation shaft Stainless steel...
  • Page 41 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 617 Rev. 6 August 2020 Figure 25 Pneumatic Cylinder Table 10. Parts List - Pneumatic Cylinder Item Description Material Head flange Carbon steel Washer Carbon steel+nitrile rubber Screw Alloy steel Cylinder tube Carbon steel Tie rod Alloy steel...
  • Page 42 Section 7: Layouts Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 26 Spring Cartridge Table 11. Parts List - Spring Cartridge Item Description Material Piston rod bushing Steel+bz+Teflon Upper spring flange Carbon steel External flange Spring steel Stainless steel STM A564-TP 630 Retainer ring Stainless steel...
  • Page 43 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 617 Rev. 6 August 2020 Figure 27 Hydraulic Cylinder Table 12. Parts List - Hydraulic Cylinder Item Description Material Piston rod bushing Steel+bz+Teflon Head flange Carbon steel O-ring NBR rubber* Piston rod seal ring Teflon + graphite* O-ring NBR rubber*...
  • Page 44 Section 7: Layouts Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 28 Hydraulic Control Unit MHP Oil tank relief valve Relief valve for automatic operation Flow regulator Relief valve for manual operation Layouts...
  • Page 45 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 617 Rev. 6 August 2020 Table 13. Parts List - Hydraulic Control Unit MHP Item Description Material Dipstick Carbon steel + Alum. Plug Carbon steel Washer Copper Hydraulic tank Carbon steel Handpump See attached table 0-ring...
  • Page 46 Section 7: Layouts Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Item Description Material Flange Carbon steel O-ring Fluorosilicon rubber* Spring Spring steel Plug Stainless steel Retainer ring Carbon steel Spring pin Carbon steel Rivet Aluminium Operation instruction plate Stainless steel Screw Carbon steel...
  • Page 47 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 617 Rev. 6 August 2020 Figure 29 Hydraulic Control Unit - Handpump Table 14. Parts List - Hydraulic Control Unit - Handpump Item Description Material Ball Stainless steel Delivery valve bush Carbon steel Suction valve bush Carbon steel...
  • Page 48 Section 7: Layouts Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Figure 30 Mechanical Manual Override Layouts...
  • Page 49 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 617 Rev. 6 August 2020 Table 15. Parts List - Jackscrew Manual Override MSJ Item Description Material Protection pipe Carbon steel Handwheel manual override ∅1250 Stainless steel Jack screw Carbon steel Engagement lever pin Stainless steel O-ring...

  • Page 50: Section 8: Date Report For Maintenance Operations

    Section 8: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual August 2020 MAN 617 Rev. 6 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 51 Installation, Operation and Maintenance Manual Notes MAN 617 Rev. 6 August 2020 This page intentionally left blank.
  • Page 52 VCIOM-04491-EN ©2020 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for information purposes only, 29017 Fiorenzuola d’Arda (PC) and while every effort has been made to ensure their accuracy, they are not...

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