Gas-over-Oil actuators, series GPO -...

Gas-over-Oil actuators, series GPO

Tyco reserves the right to change the contents without notice BIFRM-0023-EN-1007www.tycoflowcontrol-eu.com

Features• Canted scotch yoke mechanism

transforms movement of the hydrauliccylinder into a 90° rotation

• Remote operation/network solutions(Modbus or other protocols)

• Solar panel option for power supply ofsolenoid valves and electronic line breakcontrol

• Housing in fabricated carbon steel, formaximum strength

• Actuator flange can be machined tocustomer specifications

• Gas-over-oil tanks according ASME VIII Div. 1, PED 97/23 EC. Other on request

• Totally enclosed, weatherproof housing• Special coatings available for offshore or

corrosive environments

Technical dataTorque : up to 400.000 NmSupply pressure : 105 barg max.Temperature : -30 to +100°C

ApprovalsActuators are built according the followingEuropean directives:• Machinery Directive 8973/23 EC, 93/368• Low Voltage Directive EC/392, 91/368 EC• Electro-magnetic compatibility Directive

89/336 EC, 92/31 EC• ATEX 94/9/EC Directive• ‘PED’ Pressure Equipment Directive

97/23 EC

The GPO calculations are approved byLloyd Register (Machinery General DesignAppraisal) according to S.I, N° 825, pipelineSafety Regulation. All GPO actuators areindividually tested and EN 10204.3.1Bcertified.

MaterialsBody : Carbon steelCylinders : ENP/polishedPiston rods : Hard chrome

plated/polishedGuide bars : Hard chrome

plated/polishedBushing : Bronze or sintered,

with PTFE

Reliable gas-over-oil actuator for extreme applications inboth on- and offshore markets

2,5

1,5

1,0

2,0

2,5

1,5

1,0

2,0

0 9045

c

d

e

a

b


Tyco reserves the right to change the contents without notice page 2

1. General information on the scotch-yoke mechanism

Biffi gas-over-oil actuators, ‘GPO’ series for normal temperature (-30° to +80°C) or for lowtemperature (-60° to +80°C), are normally manufactured with a canted scotch-yoke mechanism.The torque curve developed by this type of actuator is most suitable to operate quarter-turn valves,particularly ball valves.

Figure 1 shows the diagrams, as a function of the angular position, of the typical required torqueof a ball valve both in opening and in closing, and the output torque of a canted scotch-yokemechanism.Figure 1 also shows the comparison between the output torque curves of a canted and asymmetric scotch-yoke mechanisms, and of a ‘constant torque’ actuator (i.e. Rack & Pinion type). These graphs demonstrate that, since the arm length and the cylinder diameter are the same,canted scotch-yoke actuators have the most suitable mechanism, both for technical andeconomical reasons, to operate quarter-turn valves.Biffi can anyway provide symmetric scotch-yoke actuators for special applications as low pressureball valves or plug valves.- Special modules for remote communication via bus (Modbus or other protocols) are available.- Special power supply of solenoid valves and electronic line break control with solar panel is also

available.

Figure 1

Closed

Torq

ue

Angular position Open

Notes

a) valve opening torque b) valve closing torque c) actual actuator output torque

(canted design)d) actual actuator output torque

(symmetric design)e) output torque of a constant torque actuator

Quality AssuranceBiffi has designed and implemented a QualityAssurance System in accordance withEuropean standard EN-29001 (ISO 9001).Biffi Italia is certified for the EnvironmentalManagement System in accordance with ISO – EN 14001. Biffi Italia is also assessed by Achilles/FirstPoint Organization. The Quality Assurance System is theinstrument for monitoring the productionprocess and the quality of the relevantservices.Biffi Quality System ensures the followingadvantages: it is a guarantee for Biffi, as thevarious tests, which are carried out, highlightall possible critical points inside theorganization, and thus make it possible to takethe necessary corrective actions and tooptimize the available resources. It is aguarantee for the customer as the control ofevery phase of the production cycle, from thequotation to the invoice, is performed within acontrolled and documented system.



2. GPO actuator assembly

Figure 2

Gas-over-oil tanks

Control group

Housing with scotch-yoke mechanism

Junction box

Flow control valves

Hydraulic cylinder

Mechanical stopper

Mechanical stopper

Hydraulic manual override



4. Scotch-yoke mechanism

The scotch-yoke mechanism shown in figure 4 transforms the linear movement of the hydrauliccylinder into a 90° rotation.The housing (1) in fabricated carbon steel provides for the coupling of the actuator to the valveflange and the support of the hydraulic cylinder; it encloses the scotch-yoke mechanism andtogether with the cover provides the mechanical protection. For the coupling to the valve, the housing is provided with a flange with threaded holes anddimensions according to the Biffi standard tables SCN 6200 and SCN 6201 (see figure 33 & 34). Ifrequired, Biffi can supply an adaptor flange machined according to the valve coupling dimensionsprovided by the customer.The yoke (2) during its rotation is contained by bronze bushings (3): one is assembled in the flangeof the housing, the other in the cover (4).The yoke has a bore with keyways to couple the valve stem, the dimensions of which areaccording to Biffi standard tables. On request Biffi can supply an insert bush with machined orunmachined bore according to the dimensions of the valve stem.The yoke receives the thrust of the cylinder from the block pin (5) by means of the bronze slidingblocks (6) which move inside the slots of the yoke arms.

3. Housing and cylinder

Materials specification

Item Name Material

1 Housing Carbon steel2 Yoke Carbon steel3 Bushing Bronze4 Cover Carbon steel5 Block pin Alloy steel6 Sliding block Bronze7 Guide block Carbon steel8 Guide bar Alloy steel (hard chrome plated)9 Bushing Bronze

10 Cylinder tube Carbon steel (ENP)11 Piston rod Alloy steel (hard chrome plated)12 Bushing Bronze13 Piston Carbon steel14 Guide ring PTFE + graphite

12

3

5

6

24

1

101413

11

8

79

Figure 3



1

Figure 4Canted scotch-yoke mechanism

1. in open position2. in intermediate position

3. in closed position

2

3

5. Cylinder

The cylinders of gas-over-oil actuators are engineered and manufactured to be used in hydraulicservice. Special care is taken to provide a smooth internal surface of the cylinder tube (10) byhoning it. The piston rod (11) slides inside the bore of the head flange guided by the bushing (12). This guidebushing has surface contact with the piston rod in bronze charged with PTFE and guarantees avery low friction coefficient. The piston (13) slides inside the cylinder tube and is guided by a PTFE ring (14) which guarantees ahigh efficiency.The piston and piston rod seals are made by PTFE rings precharged by an o-ring made of the mostsuitable compound for the severest working conditions.

The block pin is mounted in the guide block (7) where the threaded end of the cylinder piston rodis screwed.The guide block slides along the guide bar (8) by means of the bushing (9) made of sinteredbronze charged with PTFE.The bushing guarantees a very low friction coefficient.The guide bar withstands the transversal forces originated by the angle between the surface of theslots and the perpendicular to the piston rod axis.In this way the piston rod is not loaded with transversal forces, thus not wearing its guide bushingand its ring seals which are assembled in the head flange of the hydraulic cylinder.The bronze material used in the sliding parts guarantees a high efficiency of the mechanism.The angular stroke of the yoke is adjustable between 82° and 98° by means of the mechanicalstops screwed into the end flange of the hydraulic cylinder (closed valve) and into the left side ofthe housing (open valve).In case of an actuator with two cylinders, both mechanical stops are screwed into the end flangesof the cylinders.

6. Gas-over-oil tanks

The gas-over-oil tanks are used to separate the feeding gas from the hydraulic cylinder.A dipstick screwed into the upper nozzle of the tank is used to check the oil level. In the bottompart of the tank is the hydraulic filter. The tanks are normally engineered, manufactured and testedaccording to ASME VIII-DIV. 1. The tanks can also be supplied in accordance with PED EuropeanDirective 97/23 EC, or other codes on request.

Figure 5a - Piston seals

Figure 5b - Piston rod seals

Figure 6



7. Working principle

The gas-over-oil actuator is fed by pressurized gas which, after being filtered, flows through thecontrol valves into the tank relevant to the operation (opening or closing) to be performed. Thehydraulic oil contained in the tank is pressurized by the gas and flows into the relevant cylinderchamber, while the oil contained in the other chamber flows into the second tank. The cylinderpiston stroke causes the actuator operation.The oil flow from the cylinder into the tanks is adjusted by means of two flow control valves. Inthis way it is possible to adjust the stroking time of the actuator.Emergency manual override can be performed by selecting the opening and closing operation bymeans of the hand actuated directional control valve and then actuating the hand pump.

Figure 7 - Latvian Gaze, 28” ball valve with GPO Figure 8 - Samsun Station Turkey 16” ball valves with GPO

8. Valve position indication

If required, the actuator can be supplied with electric limit switches which can be adjusted alongthe complete angular stroke of the valve. The limit switches can be provided in different typesaccording to customer requirements: sealed, with contacts in inert gas atmosphere, with goldcontacts, magnetic, proximity type etc. When possible, because of dimensions, quantity andcharacteristics, the limit switches are enclosed in a weather-proof IP 68 according to IEC 529 andEN 60529 and explosion-proof enclosure, which meets the ATEX European standard with acompliance certificate issued by an approved laboratory.In the upper part of the standard Biffi limit switches enclosure there is a local position indicator,which shows the position of the valve along the angular stroke.When a remote continuous signaling of the position of the valve is required, the actuator issupplied with a position transmitter in accordance with customer requirements.If limit switches are not required, a local mechanical position indicator is provided in the upperpart of the yoke, for the continual indication of the position of the valve.

Figure 10 - Local mechanical position indicator

Figure 9 - Internal view of the electric limitswitches enclosure

Figure 12 - Control system complete with solenoid valves and ‘line break’ device



9. Actuator control system

Biffi has produced a wide range of pneumatic and hydraulic components specifically engineered tosuit the most varying needs of the customer (i.e. control mode, emergency operation, workingtemperature range, pressure range of the gas supply etc.). These components guarantee a highreliability and compact design.Every pneumatic valve is engineered to work with high pressure gas. Therefore the control groupdoes not need to be fed by means of a pressure reducer. In this way the reliability of the system isincreased.The pneumatic valves in aluminium alloy are poppet-type in order to provide bubble tightness. Thesealing seats are made of PTFE, thus granting chemical resistance, lack of sticking and aging effectsand the highest compatibility with every environment condition. The basic control system of the Biffigas-over-oil actuator mainly consists of a double 3-way 2-position control valve, which is normallypiloted by 2 solenoid valves for remote control, one for closing and one for opening. It is also possibleto locally operate this valve by means of 2 levers, one for closing and one for opening.The junction box, where all the wiring coming from the actuator electric components and from theremote control panel are connected, can be supplied complete with a local / remote selector.

The solenoids enclosures and the junction box are weather- and explosion-proof in accordancewith ATEX standard (compliance certificate issued by approved laboratory). The Biffi controlsystem is also certified by FM (U.S.A.), A.S. (Australia) and Gosgortechnadzor-EX-D (Russia).The pneumatic control valves are enclosed in a weather-proof padlockable enclosure.

Biffi can supply different types of control systems following customer requirements.Figure 11 - Control system complete withsolenoid valves



The actuator control can be made with one or more electric signals or by means of low/highpressure pneumatic signals.Automatic control groups for the actuator operation (in opening or in closing) are also available.The ‘ESD’ and the ‘line break’ devices are typical examples.The standard line break control is completely autonomous, not depending on other power/controlsources.The ‘line break’ device automatically closes the actuator when the pressure drop rate exceeds apreset value.Special versions of line break control for sour gas, liquid fluids, dirty and very humid natural gasare also available.The ‘ESD’ device automatically opens or closes the actuator when the pressure or the pressurevalue is outside the normal range of values. The pressure switch can either be pneumatic or electric. A typical example of ‘ESD’ device isshown in schematic drawing figure 26.

A typical example of ‘line break’ device is shown in schematic drawing figure 28.In case the control signal is also present at the end of the manoeuvre like for the ‘electric fail safe’system (see enclosed figure 27) and for the ‘ESD’ device, the actuator can be provided withpneumatic limit switches which cause the exhaust of the gas used for the operation at the end ofthe actuator manoeuvre. In this way the gas-over-oil tanks and all the hydraulic components areonly pressurized during the actuator operation.

Pneumatic line break system

Electric signals

16 16

8

19

3 11G

C

K

H L

D

BFEA

2

13

20

Figure 13 - Control system complete with solenoid valves and ‘line break’ device



An electronic version of the line break control is also available.

A pressure reducer or a ‘torque limiting device’ (Biffi patent) can be supplied, when the gas supplypressure varies in a wide range and when the actuator output torque must not exceed a fixedvalue in order not to damage the valve.The pressure reducer limits the output torque of the actuator by reducing the gas supply pressureat a preset value. The ‘torque limiting device’ consists of 2 pressure piloted valves, one for eachgas-over-oil tank, which stop the gas flow coming from the pneumatic control valves of theactuator and exhaust the gas enclosed in the gas-over-oil tanks when the output torque exceedsthe preset value.When the gas supply to the actuator is not always available, a storage tank engineered andmanufactured according to the applicable code and working conditions is provided. The tank isequipped with the required accessories: safety relief valve, pressure gauge, stop valve, drain valve,etc.For heavy duty service or when required by the customer, the control valves can be supplied in aspecial execution (materials or design not standard), for instance pneumatic valves according toNACE standard for sour gas service.For any particular requirements it is advisable to contact Biffi sales offices, which will provide themost suitable and convenient solutions to the various needs.

Figure 14 - Torque limiting device

Figure 15 - GPO actuator with electronic linebreak control

Figure 16 - Hand pump with directionalcontrol valve and flow control valve

10. Speed control

The speed of actuator operation is adjusted by controlling the oil flow from the cylinder to the gas-over-oil tanks by means of 2 flow control valves. These valves are mounted on the pump-distributor group. They are unidirectional and allow independent adjustment of the stroking timeboth in closing and opening. By acting on the oil flow and not on the gas, it is possible to be moreaccurate in the speed adjustment, thus granting a smoother stroke of the actuator.

11. Emergency hydraulic manual operation

The Biffi gas-over-oil actuator is supplied with hand pump and a 4-position directional control valveto operate the valve in emergency conditions in case of gas supply failure.The directional control valve has 4 positions: automatic, close, open and by-pass. In ‘automatic’position the hand pump is overridden, since in this case the actuator works by means of the gassupply. The ‘close’ and ‘open’ positions allow operating the actuator by actuating the hand pump.The ‘by-pass’ position allows for balancing the level of the oil contained in the 2 gas-over-oil tanks.A special execution assuring the priority of the remote operation is also available.



12. Assembly of actuator onto the valve

For coupling to the valve, the housing is provided with a flange with threaded holes according toBiffi standard tables SCN 6200 and SCN 6201 enclosed (see figure 33 and figure 34).

The number, dimensions and diameter of the holes are made in accordance with ISO 5211, but foractuator models 0.3 to 6 the holes are drilled on the centerline in order to allow an easierassembly of an intermediate flange, when required. This intermediate flange can be supplied whenthe valve flange cannot directly match the actuator flange in its ‘standard’ configuration. For thebiggest actuator models, the actuator flange can be machined in accordance with the valve flangedimensions.The yoke has a bore with keyways for coupling to the valve stem, the dimensions of which areaccording to Biffi standard tables SCN 6200 and SCN 6201.

If required, for the standard models size 0.3 to 6, Biffi can supply an insert bush with unmachinedbore in accordance with Biffi standard table SCN 6202 enclosed (see figure 36). On request theinsert bush bore can be machined by Biffi to couple the valve stem, provided its dimensions matchthe maximum stem acceptance of the bush according to Biffi table TN 1005, enclosed (page 28).The particular execution of the flange and bushing allow the actuator to be rotated by 90° in 4 different positions according to the following figure.

The Biffi insert bush with 2 external keys at 45° allows positioning the keyway for the valve every90°. Consequently actuator can be mounted in 4 positions at 90° on top of the valve.For the biggest actuator models, the bore of the yoke can be machined according to thedimensions of the valve stem.

Figure 17 - Housing with scotch-yoke mechanism. Insert bush arrangement in 4 positions at 90°

Insert bush turned upside down

Rotation 180°Around verticalBase position

Rotation 180°Around axis

A-A from pos. (2)

Rotation 180°Around axis

A-A from pos. (1)

Housing

Insert bush (1)

Drive sleeve

Snap ring

Adaptor flange

Flow line

Drive sleeve

Insert bush (1)

N.4

hol

es fl

ange

N.8

hol

es fl

ange

A

A

A

A

A A

AA

Pos.(1)

Pos.(2) Pos.(3) Pos.(4)



13. Actuator power supply

The Biffi gas-over-oil actuator is engineered and manufactured to work with a pressure supplyvarying from 7 bar to 105 bar (from 100 psi to 1500 psi). Biffi can also provide actuators working atpressure supply values outside the above range.

The advantage of the Biffi gas-over-oil actuator is that it functions with the gas flowing in thepipeline without requiring another power source supply.Each actuator is also provided with a connection port to be fed by a separate supply line from agas storage unit or by bottled gas.The Biffi gas-over-oil actuator is supplied with a filter to avoid the entrance of particles whichmight prevent the proper working of the pneumatic components. In case of wet gas, Biffi cansupply a filter-condensate separator-dehydrator unit.

14. Final testing

It is very important to point out that Biffi tests100% of the actuators. In order to do so, Biffitesting department is equipped withsophisticated test rigs which allow to checkthe correct working of the actuator with allthe foreseen control modes.The testing department is also equipped withelectronic devices which allow to measurevarious actuators parameters like the outputtorques, the values of which are written onthe test certificate attached to each actuator.The tests are carried out in accordance withBiffi internal specifications and they can beintegrated with additional tests in accordancewith customer requirements.These tests can be witnessed by third partyauthorities or by the customer, in accordancewith contractual terms.

Figure 18

Figure 19

*3.3C-75 3000 22 64 31 40 38*0.3C-100 3000 41 115 57 73 69*0.9C-100 9000 47 132 65 85 80*0.9C-135 9000 87 243 120 154 146*1.5C-135 15000 108 304 150 212 169*1.5C-175 15000 184 512 255 356 287*3C-135 30000 176 493 244 346 285*3C-175 30000 298 829 412 582 482*6C-175 60000 348 970 482 679 565*6C-200 60000 451 1320 624 887 732*6C2-200 60000 947 2419 1311 1695 153614C-235 120000 700 1912 969 1360 111514C-280 120000 996 2715 1379 1931 158814C2-235 120000 1448 3700 2005 2631 230914C2-280 120000 2059 5261 2851 3741 328218C-235 180000 805 2197 1114 1564 128318C-280 180000 1146 3122 1586 2220 182718C2-235 180000 1666 4255 2306 3025 265618C2-280 180000 2368 6050 3278 4300 415232C-235 300000 955 2616 1323 1812 152932C-280 300000 1360 3707 1883 2573 217732C2-235 300000 1978 5052 2738 3506 316532C2-280 300000 2812 7183 3892 4984 449950C-235 400000 1073 2934 1486 2013 169950C-280 400000 1528 4165 2116 2858 241950C-300 400000 1739 4782 2407 3281 275150C2-235 400000 2198 5614 3042 3895 351750C2-280 400000 3124 7981 4325 5538 499950C2-300 400000 3568 9121 4943 6329 5713



Notes

1. * standard models2. Max. allowable pressure 100 bar

(static pressure applicable to fully strokedactuator against the travel stops)

3. For Symmetric yoke, please change C with S

GPO actuators performance table

Canted yoke Symmetric yokeActuator Max. operating Output torque Output torque Output torque Output torque Output torquemodel torque (Nm) at 45° (Nm/bar) at 0° (Nm/bar) at 90° (Nm/bar) at 0° (Nm/bar) at 90° (Nm/bar)

Figure 20 - Typical GPO configuration

0.3C*-75 0.7 1.6 4.3 38 80.3C*-100 1.2 2.7 4.3 65 7.60.9C*-100 1.4 3.2 7.5 76 13.50.9C*-135 2.4 5.2 7.5 130 131.5C*-135 3 6 7.5 162 12.51.5C*-175 5 9 12 270 203C*-135 5 9 19 270 333C*-175 8 14 19 432 336C*-175 10 17 24 392 406C*-200 12 20 24 470 406C*2-200 24 40 49 470 8014C*-235 18 30 35 706 6014C*-280 26 42 50 1020 8514C*2-235 36 59 75 706 12014C*2-280 51 84 96 1020 17018C*-235 21 34 40 824 7018C*-280 30 48 60 1176 10018C*2-235 41 68 82 824 13518C*2-280 59 97 123 1176 19032C*-235 25 40 50 980 8032C*-280 35 57 75 1372 11532C*2-235 48 80 96 980 16032C*2-280 68 113 130 1372 22050C*-235 27 44 60 1060 9050C*-280 39 3 82 1530 13050C*-300 45 72 96 1765 15050C*2-235 52 85 96 1060 17050C*2-280 76 125 140 1530 25050C*2-300 88 144 171 1765 290

Gas-over-Oil actuators, series GPOactuators technical data


Figure 21 - GPO bi-cylinder actuator complete with ‘line break’ device

Note

For Symmetric yoke, please change C with S

GPO actuators technical data

Actuator Oil Gas Tank Hand pump Oilmodel displacement consumption capacity operations content

(lt.) (lt.) (lt.) per stroke (lt.)

Figure 22 - GPO 6S-200 complete with‘torque limiting device’



Note

The operating diagram is drawn with controlvalves not actuated

Local control

Item Name

1 Double-acting gas-over-oil actuator2 Hydraulic manual override

A – Hand pumpB – Adjustable relief valveC – Hand-operated directional control valve

3 Unidirectional flow regulator (adjustable setting)4 Gas-hydraulic tank5 Hydraulic filter6 Stop valve7 Gas filter/Condensate separator8 Dust excluder with check valve9 Control valves enclosure with vent valve

10 Double 3/2 n.c. hand-operated/spring-return valvePC – 3/2 n.c. hand-operated/ spring pilot valve (to close)PO – 3/2 n.c. hand-operated/spring pilot valve (to open)DC – 3/2 n.c. pneumatic pilot/spring-return valve (to close)DO – 3/2 n.c. pneumatic pilot/spring-return valve (to open)

11 Electric microswitches

Local controlPress lever of valve 10-PO to open or 10-PC toclose with power supply

Manual operationSelect by the valve 2C the opening or closingoperation and actuate the hand pump 2A

Pneumatic connectionHydraulic connection

11

1

Electric connectionto microswitches

C

3-O

4-O4-C9

10

8

7

6

Gas exhaust

Auxiliary gas supplyconnection

Figure 23 - Local control

Gas supplyconnection

Close

Open

5

2

A

B

5

3-C

E.M.

PC PO

DC DO



Note


Local and remote control

Item Name




10 Double 3/2 n.c. solenoid valve with manual overridePC – 3/2 n.c. pilot solenoid valve, manual override (to close)PO – 3/2 n.c. pilot solenoid valve, manual override (to open)DC – 3/2 n.c. pneumatic pilot/spring-return valve (to close)DO – 3/2 n.c. pneumatic pilot/spring-return valve (to open)

11 Electric microswitches12 Terminals enclosure

Figure 24 - Local and remote control

Pneumatic connectionHydraulic connectionElectric connection

Electric remote controlEnergize solenoid valve 10-PC to close or 10-PO to open the actuator, during the entirevalve stroke.Solenoid valves must be de-energized at theend of the actuator operation.

Local control Press lever of valves 10-PO to open and 10-PCto close with power supply

Manual operation Select by the valve 2C the opening or closingoperation and actuate the hand pump 2A

10

9 4-C 4-O

5 5

3-C3-O

2

Gasexhaust

6

7 8

12

Open

Close

Electric connectionto solenoid valvesand microswitches

DC DO

POPC

1

11E.M.



C



Electric remote controlEnergize solenoid valve 10-PC to close or 10-PO to open the actuator, during the entirevalve strokeSolenoid valves must be de-energized at theend of the actuator operation

Local control Press lever on valves 10-PO to open or 10-PCto close with power supply


Torque limiting deviceWhen the actuator output torque exceeds theset value, the torque limiting switch 13 stopsthe gas flow to the relevant gas-hydraulic tank4, and the enclosed gas is exhausted

Local and remote control, torque limiting device

Item Name





11 Electric microswitches12 Terminals enclosure13 Torque limit switch Note



Close

Open

8

6

7

DC DO

Figure 25 - Local and remote control, torque limiting device


Electric connection tosolenoid valves andmicroswitches

Gasexhaust


12

11

1

9

10

T.E.

POPC

E.M.

C

3-C3-O

5

2

5

13-O13-C

4-C 4-O

A

B

15*



Local and remote control, emergency low pressure shut down

Item Name





11 Electric microswitches12 Terminals enclosure13 Mechanical filter14 Check valve15 Gas storage tank16 Needle valve17 Pressure gauge18 Relief valve19 Manual drain valve20 N.o. pneumatic pressure switch (adjustable setting)21 3/2 n.o. cam-actuated/spring-return valve22 3/2 n.o. pneumatic pilot/hand-return valve23 Higher pressure shuttle valve

Electric remote controlEnergize solenoid 10-PC to close or 10-PO toopen the actuator during the entire valvestroke. Solenoid valves must be de-energizedat the end of the actuator operation.

Local operationPress lever of valves 10-PO to open or 10-PCto close with power supply

Manual operationSelect by the valve 2C the opening or closingoperation and actuate the hand pump 2A

Emergency shutdown operationThe pressure to be controlled is connected tothe pressure switch (20) pilot.When the pressure decreases below the setpoint of the pressure switch (20), a pressuresignal pilots the valve (22) to inhibit openingoperation and power valve (10-PO) causes theactuator closing.The pilot pressure must be re-established andthe opening operation inhibition valve must bemanually reset before the actuator can bereopened

Note

The operating diagram is drawn for solenoidvalves coils not energized, low pressure in theESD device pilot line, and no pressure in thegas supply line and into the storage tank

OpenClose9

4-C 4-O

2

5A

B

5

3-O 3-C

1

11

8

Figure 26 - Local and remote control, emergency low pressure shut down

C

E.M.

T.E.12

7

Gasexhaust

Auxiliary gas supplyconnection Electric connection to

solenoid valves andmicroswitches

Esd device pilotconnection

* = Optional

6B

21

22

20

10

23PO

DCDO

PC

18*

19*

17*

16* 14*

13* 6A Gas supplyconnection Pneumatic connection

Hydraulic connectionElectric connection




Electric remote controlEnergize solenoid 21 to open, de-energize toclose the actuator: in case of electric supplyfailure the actuator moves automatically inclosing At the end of actuator strokes the valves 24are actuated and cause the exhaust of the gasutilized for the operation

Local controlMove the valve 20 to ‘local operation’Press lever on valves 10-PO to open or 10-PCto close with power supply

Manual operationMove the valve 20 to ‘local operation’Select by the valve 2C the opening or closingoperation and actuate the hand pump 2A

24-C

DC DO

Figure 27 - Local and remote control, electric fail safe

1

11128

20

22

21

5

2

5

3-C3-O

24-O

910

23 23

T.E.

18*

17A*

16A*

* = Optional

15*

19*

14*

E.M.

16B

17B

Gas exhaust Electric connectionto solenoid valve andmicroswitches


Gas supplyconnection6

7

POPC4-O4-C

C

Close

Open

Local and remote control, electric fail safe

Item Name




10 Double 3/2 n.c. hand-operated/spring-return valvePC – 3/2 n.c. hand-operated/ spring pilot valve (to close)PO – 3/2 n.c. hand-operated/spring pilot valve (to open)DC – 3/2 n.c. pneumatic pilot/spring-return valve (to close)DO – 3/2 n.c. pneumatic pilot/spring-return valve (to open)

11 Electric microswitches12 Terminals enclosure13 Mechanical filter14 Check valve15 Gas storage tank16 Needle valve17 Pressure gauge18 Relief valve19 Manual drain valve20 3/2 hand-operated valve21 3/2 n.o. solenoid/spring-return pilot valve22 3/2 n.o. pneumatic pilot/spring-return valve23 Higher pressure shuttle valve24 3/2 n.o. cam-actuated/spring-return valve

Note

The operating diagram is drawn for solenoidvalve coil not energized, no pressure in thegas supply line and into the storage tank,valve in intermediate position

13*

Local and remote control, line break device

Item Name





11 Electric microswitches12 Terminals enclosure13 Mechanical filter



A

16*

15*

19*

14*

C

B

L.B. Devicetest ports

L.B.23

DODC

EF

Figure 28 - Local and remote control, line break device


Electric remote controlEnergize solenoid valve 10-PC to close or 10-PO to open the actuator, during the entirevalve strokeSolenoid valves must be de-energized at theend of the actuator operation

Local control Press lever on valves 10-PO to open or 10-PCto close with power supply

2122

* = Optional

A

BC

108

9

7A T.E.

6C

B

5 5

2

1

3-O

4-C 4-O

7B

12

PC PO

Gasexhaust

17*

18*

13A* 6A*

13B* 6B*

24

Line breakdevice

connection


3-C

A

11E.M.

Gas supply connection(upstream the valve)

Gas supply connection(downstream the valve)

Electric connection to solenoidvalves and microswitches

CloseOpen

Note



Line break operationA rate of pressure drop in the pipeline causesa differential pressure across the diaphragmvalve 22. When the differential pressure ishigher than the preset value, the diaphragmvalve 22 trips and pilots the valve 20 to inhibitopen operation and the power valve 10Ccauses the actuator to close.

After the line break intervention, the inhibitionvalve (20) must be manually reset before theactuator can be reopened.The line break pilot has to be connected tothe pipeline (downstream the valve) and thepressure intake has to be separate from thegas supply pressure intake

14 Higher pressure shuttle valve (double check valve)15 Gas storage tank16 Needle valve17 Pressure gauge18 Relief valve19 Manual drain valve20 3/2 n.o. pneumatic pilot/hand-return valve21 Shuttle valve device

A – Check valveB – Low pressure vent valveC – Stop valve for pressure gaugeD – Pressure gaugeE – 2/2 hand-operated valveF – Higher pressure shuttle valve

22 2/2 n.c. diaphragm pilot valve (adjustable)23 Check valve with orifice for line break device

A – Check valve with orificeB – Stop valve

24 Reference tank for line break device



15. Sizing of gas-over-oil actuators

Normally the power gas for GPO actuator feeding is taken directly from the gasline. This meansthat the pressure of the gasline is the same used by the actuator. Being the pipeline pressurenormally not constant, a minimum and a maximum value of the pipeline pressure is defined by thetechnical specifications.With the minimum pressure the actuator must move the valve with the minimum ΔP. With themaximum pressure the actuator must move the valve with maximum ΔP.Usually the most critical situation for the actuator is the running torque of the valve when theminimum pipeline pressure is available.Only when the gas supply is taken from an independent source (separate pipeline, emergencytank, separate control system) the actuator with the minimum supply pressure must be able tomove the valve with the maximum ΔP.

Particular attention must be paid to the opening of vent valves and by-pass valves, generally ofsmall size. In this case the gas speed and the ΔP across the valve generate a significant dynamictorque to close the valve not only near to the closing position, but along the valve stroke. Thevalve makers must carefully evaluate this situation and provide the correct torque values for thereal operating condition of the valve. The rule of thumb for this application is to consider the actuator supply at minimum pressure (i.e.25 barg) to move the valve with the max ΔP (i.e. 100 barg).

16. Gas-over-oil actuators ‘HYGLA’ for Linear Valves

For the motorization of linear valves, as through-conduit gate valves frequently used in the gaspipelines, Biffi can also propose the proper gas-over-oil actuators of the ‘HYGLA’ series.

HYGLA actuators utilize the same high-pressure controls used for quarter-turn actuators GPO.Proper pedestals with flanges and adjustable stem joint to meet the valve top mounting design arenormally supplied.

In order to keep the valve in position, the control systems usually include the hydraulic lockingdevice with double piloted check valves with thermal relief function or mechanical lock piloted bythe power gas.

Figure 29

0.3*-75 947 615 862 515 268 186 427 147 72 790 200 319 222 532 292 221 189 345 70 155 332 300 102 SCN 6200 1250.3*-100 969 615 862 515 268 186 427 147 72 790 200 319 222 554 292 221 189 345 70 155 332 300 102 SCN 6200 1400.9*-100 1043 681 829 551 304 222 463 147 12 817 243 342 245 593 315 244 250 393 80 185 367 377 142 SCN 6200 1700.9*-135 1110 681 829 551 304 222 463 147 12 817 243 342 245 660 315 244 250 393 80 185 367 377 142 SCN 6200 1901.5*-135 1152 742 829 552 305 223 464 147 11 818 284 362 293 702 335 264 270 413 100 185 367 377 142 SCN 6200 2101.5*-175 1213 742 1157 552 305 223 464 147 11 1146 284 362 293 763 335 264 270 413 100 185 367 377 142 SCN 6200 2503*-135 1555 917 1313 565 318 234 476 147 20 1293 371 443 391 1032 416 345 319 493 160 235 438 337 168 SCN 6200 3903*-175 1623 917 1313 565 318 234 476 147 20 1293 371 443 391 1100 416 345 319 493 160 235 438 337 168 SCN 6200 410

Gas-over-Oil actuators, series GPOoverall dimensions


Notes

X = 1/2 NPT gas supply connectionY = 1/4 NPT emergency gas supply

connectionW = 1 NPT electric connectionZ = 25 mm lifting holes diameterWeights are referred to base construction(without adaptor)* = C For canted yoke

S For symmetric yoke

a

y

A

l m

ut

X

p

qr

B

n

o

Exhaust

z z

ed

fg

C

w

h i

Lifting points

cb

Figure 30 - TN 1037-1

Dimensions in mmActuator A B C a b c d e f g h i l m n o p q r s t u Ø Coupling Weightmodel dwg (Kg)

Ø

6*-175 1785 1160 1120 602 355 271 512 202 77 1043 480 279 430 1154 241 170 398 680 185 455 478 90 219 SCN 6200 5156*-200 1855 1160 1120 602 355 271 512 202 77 1043 480 279 430 1224 241 170 398 680 185 455 478 90 219 SCN 6200 550

14*-235 2098 1223 1475 715 468 384 618 202 59 1416 543 392 496 1252 354 283 381 660 200 630 501 0 219 SCN 6201 95014*-280 2098 1223 1865 715 468 384 618 202 59 1806 543 392 496 1252 354 283 381 660 200 630 501 0 219 SCN 6201 132018*-235 2255 1230 1525 729 482 398 682 202 37 1488 550 456 564 1355 418 347 384 870 230 630 726 0 219 SCN 6201 119018*-280 2255 1230 1400 729 482 398 682 202 37 1363 550 456 564 1355 418 347 441 870 230 630 726 0 273 SCN 6201 143032*-235 2446 1548 1865 750 503 419 703 202 80 1785 660 430 610 1556 392 321 543 920 270 630 890 0 219 SCN 6201 158032*-280 2446 1548 1850 750 503 419 703 202 80 1770 660 430 610 1556 392 321 570 920 270 630 890 0 273 SCN 6201 182050*-235 2610 1825 1540 780 533 449 733 202 92 1448 685 355 698 1700 317 246 551 1140 300 860 900 42 273 SCN 6201-1 180050*-280 2610 1825 1400 780 533 449 733 202 92 1308 685 355 698 1700 317 246 592 1140 300 860 900 42 355 SCN 6201-1 212050*-300 2610 1825 1500 780 533 449 733 202 92 1408 685 355 698 1700 317 246 592 1140 300 860 900 42 355 SCN 6201-1 2290

s



a

y

Ø

A

l m

t

X

p

q

r

B n o

Exhaust

ed

fg

C

w

h i

Lifting points

Lifting points

c

b

u

Figure 31 - TN 1037-2

Notes





6*-2-200 2396 1160 1290 602 355 271 512 202 77 1213 480 279 1172 1224 241 170 425 680 185 455 478 90 273 SCN 6200 70014*2-235 2445 1223 1842 715 468 384 618 202 59 1783 543 392 1193 1252 354 283 410 660 200 630 501 0 273 SCN 6201 140014*2-280 2445 1223 1400 715 468 384 618 202 59 1341 543 392 1193 1252 354 283 452 660 200 630 501 0 356 SCN 6201 162018*2-235 2642 1230 1225 729 482 398 682 202 37 1188 550 456 1287 1355 418 347 452 870 230 630 726 0 356 SCN 6201 155018*2-280 2642 1230 1737 729 482 398 682 202 37 1700 550 456 1287 1355 418 347 452 870 230 630 726 0 356 SCN 6201 180032*2-235 3032 1548 1400 750 503 419 703 202 80 1320 660 430 1476 1556 392 321 570 920 270 630 890 0 356 SCN 6201 195032*2-280 3032 1548 1824 750 503 419 703 202 80 1744 660 430 1476 1556 392 321 570 920 270 630 890 0 356 SCN 6201 222050*2-235 3315 1825 1400 780 533 449 733 202 92 1308 685 355 1615 1700 317 246 542 1140 300 860 900 42 356 SCN 6201-1 222050*2-280 3315 1825 1400 780 533 449 733 202 92 1308 685 355 1615 1700 317 246 592 1140 300 860 900 42 457 SCN 6201-1 248050*2-300 3315 1825 1542 780 533 449 733 202 92 1450 685 355 1615 1700 317 246 592 1140 300 860 900 42 457 SCN 6201-1 2700



Notes




a

y

Ø

A

l m

t

X

p

q

r

B n o

Exhaust

ed

fg

C

w

h i

Lifting points

Lifting points

cb

u

s

Figure 32 - TN 1037-3


0.3 240 93 165 M20 4 5 17 127 70 12 75.60.9 310 112 254 M16 8 5 19 150 86 14 93.61.5 360 144 298 M20 8 6 19 190 112 18 1193 430 195 356 M30 8 9 23 200 157 25 167.86 520 250 406 M36 8 14 29 260 200 28 212.8

Gas-over-Oil actuators, series GPOcoupling dimensions


Ød4

h2

W

45°

D10

Drive sleeve

Flow line

Top view of the scotch yoke mechanism(actuator shown in closed position)

N. Threaded holes

N.8

hol

es fl

ange

N.4

hol

es fl

ange

H m

ax

Ød1 max

P.C.D., number and size according to ISO 5211 (but the holes are on centerlineinstead of stradole the centerline)

Ød5 +0.4+0.1

Figure 33 - SCN 6200

Ød2 +0.10

Ød3 ±0.2

Øh1

+0.

50

k +0.40

Note

P.C.D., number and size according to ISO 5211(but the holes are on centerline instead ofstraddle the centerline)

Dimensions in mm

Actuator Ød1 Ød2 Ød3 Ød4 N h1 h2 H max Ød5 W Kmodel

14 580 250 483 M36 12 10 29 340 175 45 195.818 680 290 603 M36 16 12 32 350 200 45 220.832 780 290 603 M36 16 12 32 400 220 50 242.8



Note

P.C.D., number and size accordingto ISO 5211


Ød4

h2

Drive sleeve

H m

ax

Ød1 max

Ød2 +0.10

Ød3 ±0.2

Øh1

+0.

50

N. Threaded holes

N.12

hol

es fl

ange

N.16

hol

es fl

ange

W D10

Flow line


Ød5 +0.2+0.1

k+

0.4

0

Dimensions in mm


50 800 315 698 M36 24 10 32 430 240 56 264.860 840 315 698 M36 24 10 32 430 240 56 264.8




Drive sleeve

Flow line

Flange sizing according to ISO

N. Threaded holes

Figure 35 - SCN 6201-1

H m

ax

Øh1

+0.

50

Ød4

h2

W D10

Ød1 max

Ød2 +0.10

Ød3 ±0.2

Ød5 +0.2+0.1

k+

0.4

0

Notes

- Insert bush supplied by Biffi withunmachined boreBlind insert on requestFor maximum stem acceptance see tableon page 28

- Fixing bolts and nuts supplied by Biffi onlyon request

- Different values of insert protrusion K onrequest

Dimensions in mm


0.3 240 93 165 M20 4 5 17 23 70 20 1060.9 310 112 254 M16 8 5 19 41 86 20 1301.5 360 144 298 M20 8 6 19 53 112 22 1573 430 195 356 M30 8 9 23 73 157 32 1626 520 250 406 M36 8 14 29 109 200 35 214

Ø 2 +0.10

Øh1

+0.

50



Notes

- Insert bush supplied by Biffi withunmachined boreBlind insert on requestFor maximum stem acceptance see tableon page 28

- Fixing bolts and nuts supplied by Biffi onlyon request

- Different values of insert protrusion K onrequest

h2

Drive sleeve

Snap ring

Housing

Insert bush (1)

Flow line

N.8

hol

es fl

ange

N.4

hol

es fl

ange

H

K (3

)

Ø I

Ø E

Ød3 ±0.2

Ød1 max

Ød4(2) Adaptor flange

N. Threaded holes


Dimensions in mm


W

S max

0.3 2500 52 (14) 55 46 64 1200.9 7000 66 (16) 70 55 77 1401.5 12000 85 (18) 90 73 103 1803 25000 120 (32) 130 104 147 1906 50000 150 (36) 170 133 188 250

M8 20M10 40M12 70M14 110M16 160M20 320M22 420M24 550M27 800M30 1100M33 1400M36 1700



Notes

* S max: maximum external diameter in caseof rounded edge

** Without adaptor flange- Key according to UNI6604 or DIN6885 sh.1

or BS4235 part 1, or ISO773, or equivalent- The listed max acceptance values are

applicable for stems with keyway parallel orperpendicular to the flow line and forsquare stems with diagonal in parallel tothe flow line

1

2

Coupling bolts tightening torque

Thread size Recommended tightening torque (Nm)

Table TN 1005 - stem acceptance for insert bush (dim in mm)

Actuator Max. Max. stem Max. stem Square stem2 Max. stem

model operating diameter diameter with protrusion **

torque (Nm) with square key rectangular

(key dimension)1 key1 (•) W S*

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