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BIFFI HLDAS Installation, Operation And Maintenance Manual

Double thrust spring-return hydraulic linear actuator
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Biffi HLDAS
Double Thrust Spring-Return Hydraulic Linear Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manuals 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 723 Rev. 0
June 2024

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  • Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manuals 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 Notes Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 This page is intentionally left blank.

  • Page 3: Table Of Contents

    Installation, Operation and Maintenance Manual Table of Contents MAN 723 Rev. 0 June 2024 Table of Contents Section 1: General Warnings Generalities ......................1 1.1.1 Applicable Regulation ................1 1.1.2 Terms and Conditions ................2 Identification Plate ..................... 2 Introducing the Actuator .................. 3 Data Sheet ......................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Section 6: Troubleshooting Failure or Breakdown Research ..............27 Section 7: Layouts Spare Parts Order ....................28 Parts List for Maintenance and Replacement Procedure .......29 Section 8: Date Report for Maintenance Operations Date Report for Maintenance Operations ............33 Table of Contents...

  • Page 5: Section 1: General Warnings

    Biffi Italia s.r.l. pays the highest attention to collecting and verifying the documentation contained in this Installation, Operation and Maintenance (IOM) manual. However, Biffi Italia s.r.l. is not liable for any mistakes contained in this manual, for damage or accidents due to the use of the latter. The information contained is of exclusive reserved ownership of Biffi Italia s.r.l.

  • Page 6: Terms And Conditions

    MAN 723 Rev. 0 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

    MAN 723 Rev. 0 June 2024 Introducing the Actuator HLDAS double thrust spring-return hydraulic linear actuators are suitable for the operation of linear valves (wedge gate valves, through conduit gate valves) for ON-OFF and modulating heavy-duty service with rising-stem or that requiring an high thrust value in the first phase of valve opening and with lower values during the complete stroke.

  • Page 8: Data Sheet

    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 9: Section 2: Installation

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 723 Rev. 0 June 2024 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 (Section 1.2).
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Figure 4. Lifting Points for HLDAS Actuators >F Figure 5. Lifting Points Placed on Top of Cylinder, Suitable For Lifting Procedure With Vertical Axis 2xG1 Installation...

  • Page 11: Storage

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 723 Rev. 0 June 2024 Storage If the actuator needs storage before installation, follow these steps: • Place it on a wood surface in order not to degrade the area of the valve coupling.

  • Page 12: Actuator Assembly On The Valve

    Section 2: Installation Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 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 13 Installation, Operation and Maintenance Manual Section 2: Installation MAN 723 Rev. 0 June 2024 To assemble the actuator onto the valve by bracket with threaded joint, proceed as follows: Figure 7. Pedestal With Threaded Coupling Joint Table 1. Parts List Item Description Stud bolt...
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 To assemble the actuator onto the valve by bracket with shell joint, perform the following operations: Figure 8. Pedestal With Shell Coupling Joint Table 2. Parts List Item Description Stud bolt...
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation MAN 723 Rev. 0 June 2024 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.

  • Page 16: Hydraulic Connections

    Section 2: Installation Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Hydraulic Connections WARNING Check that the values of hydraulic 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, fittings and connections appropriate per type, material and dimensions.

  • Page 17: Commissioning

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 723 Rev. 0 June 2024 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 damaged during transport. If necessary, repair the damage to the paint coating.

  • Page 18: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Section 3: Operation and Use Operation Description The supply fluid pressurizes the hydraulic double cylinder chamber relevant to the operation to carry out (opening or closing) (see following pages). This pressure starts the linear motion of the piston and the consequent motion of the valve stem that is coupled.

  • Page 19: Residual Risks

    Refer to specific document: operating diagram furnished. WARNING Refer to applicable control schematic in supplied documentation. The HLDAS actuators can have a local and/or remote control system which controls the oil supplied by a power pack for the “normal” actuator operation. Operation and Use...
  • Page 20 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Figure 10. Example of Remote Control Operations CLOSE 526B 354A Operation and Use...

  • Page 21: Calibration Of Microswitches (With Safety Instruction For Limit Switch Box Only)

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 723 Rev. 0 June 2024 Electric remote control to open • Energize permanently the solenoid valves 451A/B. • The opening time is adjustable by the flow regulator 526A. Electric remote control to close by HIPPS (High Integrity Pressure Protection System) •...

  • Page 22: Calibration Of The Operation Time

    Calibration of the Operation Time For actuator models with control system, it’s possible to regulate the speed of actuator operations. 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.

  • Page 23: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 723 Rev. 0 June 2024 Section 4: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade, according to IEC 61508, the functionality of the actuator must be checked at regular intervals, as described below. For safety related applications, the following test operation has to be performed: Full stroke of actuator once a year.

  • Page 24: Section 5: Maintenance

    Installation, commissioning and maintenance, and repair works should be carried out by qualified staff. Periodic Maintenance HLDAS actuators are designed to operate long-term in heavy-duty operating conditions without maintenance needs. NOTICE Periodicity and regularity of inspections is particularly influenced by specific environmental and working conditions.

  • Page 25: Extraordinary Maintenance

    If the service is not special (i.e., Oxygen, Hydrogen or other mentioned during the offer stage). Use an equivalent or better product in compliance with the grease proposed in the actual scope of supply by Biffi Fiorenzuola. Your grease supplier can verify and propose an alternative product at your responsibility. Maintenance...

  • Page 26: Replacement Of Cylinder Seals

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 5.2.2 Replacement of Cylinder Seals Refer to Figure 13. WARNING Before carrying out any maintenance operation, it is necessary to close the hydraulic feed line and exhaust the pressure from the actuator cylinder and from the control unit to ensure safety of maintenance staff.
  • Page 27 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 723 Rev. 0 June 2024 To replace the piston seal ring (25), proceed as follows: Remove the existing PTFE seal ring (25) with its O-ring from their groove. Clean the groove carefully and lubricate it with a protective oil or grease film. Assemble the new O-ring into its groove and lubricate it with a protective oil or grease film.
  • Page 28 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Figure 12. Double Thrust Spring-Return Hydraulic Linear Actuator Sectional Drawing Maintenance...
  • Page 29 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 723 Rev. 0 June 2024 Table 5. Parts List Item Description Material Carbon steel Stud bolt Carbon steel Support joint Carbon steel Index Stainless steel Screw Stainless steel Connecting joint ASTM A564/A564M TP630 H1150D Screw Carbon steel Bushing...

  • Page 30: Dismantling And Demolition

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Dismantling and Demolition Before starting the disassembly, a large area should be created around the actuator so as to allow any kind of movement without problems of further risks created by work site.

  • Page 31: Section 6: Troubleshooting

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

  • Page 32: 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 (Section 1.2) for any specific spare part for a specific actuator model.

  • Page 33: Parts List For Maintenance And Replacement Procedure

    Installation, Operation and Maintenance Manual Section 7: Layouts MAN 723 Rev. 0 June 2024 Parts List for Maintenance and Replacement Procedure Figure 13. Pedestal With Coupling Joint Table 7. Parts List Item Quantity Description Material Pedestal Carbon steel Antirotation shaft Stainless steel Scraper ring flange Stainless steel...
  • Page 34 Section 7: Layouts Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Figure 14. Spring Cartridge Table 8. Parts List Item Quantity Description Material Closing flange Carbon steel External tube Carbon steel Upper spring flange Carbon steel Lower spring flange Carbon steel Piston rod guide tube Carbon steel...
  • Page 35 Installation, Operation and Maintenance Manual Section 7: Layouts MAN 723 Rev. 0 June 2024 Figure 15. Hydraulic Double Cylinder Layouts...
  • Page 36 Section 7: Layouts Installation, Operation and Maintenance Manual June 2024 MAN 723 Rev. 0 Table 9. Parts List Item Quantity Description Material Head flange S355J2 UNI EN 10025-2 Piston rod seal ring PTFE + graphite + NBR 226 70 Sh Piston rod seal ring PTFE + graphite + NBR 226 70 Sh Back-up ring...

  • Page 37: Date Report For Maintenance Operations

    Installation, Operation and Maintenance Manual Section 8: Maintenance Operations MAN 723 Rev. 0 June 2024 Section 8: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery ): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 38 FCIM-20147-EN © 2024 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for informational purposes 29017 Fiorenzuola d’Arda (PC) only, and while every effort has been made to ensure their accuracy, Italy...