1

INSTALLATION, COMMISSIONING

AND MAINTENANCE MANUAL

MM-018-1-E

DOUBLE ACTING

GAS OVER OIL ACTUATORS

GO SERIES

Rev. Description Pages Date Issued by Approved by 00 Issue 45 24.03.05 Cocliti Pisaroni 01 Section B - Par. 1 revised 45 20.07.05 Cocliti Pisaroni 02 Sections (B – E –F) revised 47 15.02.06 Cocliti Pisaroni

Rotork Fluid System S.r.l Via del Casalino, 6 55012 Tassignano, Lucca - Italy

tel. (+39) 0583.93061 fax (+39) 0583.934612 http://www.Rotork .com E-mail: fluid@fluidsystem.it

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File GO_INDEX

INDEX

• INTRODUCTION page 3 • SECTION (A) page 4 1. GO series actuator description page 5 • SECTION (B) page 6 1. Checks to be carried out upon delivery page 7 2. Storage page 8 3. Safety Considerations page 9 4. Instructions for assembling the actuator onto the valve page 10 • SECTION (C) page 11 1. Setting of angular stroke page 12 to 13 • SECTION (D) page 14 1. Setting of electric limit switches page 15 to 16 • SECTION (E) page 17 1. Arrangement for start-up and actuator/line connections page 18 to 20 2. Start-up page 21 3. Line break page 22 to 24 • SECTION (F) page 25 1. Maintenance and instructions for changing oil in the tanks page 26 2. Gas / oil tanks oil filling instructions and hydraulic circuit purge page 27 • SECTION (G) page 28 1. Replacement of cylinder seals page 29 to 31 • SECTION (H) page 32 1. Lubrication page 33 2. Hydraulic oil features page 34 • SECTION (I) page 35 1. Typical sectional drawings and parts-list page 36 to 41 • SECTION (L) page 42 1. Instructions for actuator lifting page 43 • SECTION (M) page 44 1. Operating instructions for electric control systems page 45 to 46 2. Features of the Rotork limit switch box type MB1 page 47

3

File GO_INTR.

INTRODUCTION

This manual is produced to enable a competent user to install, operate, adjust, inspect, and maintain Rotork Fluid System GO Range actuators. It is users responsibility to follow the instructions in this manual as well as any additional documentation that has been supplied regarding the actuator or the accessories supplied by Rotork Fluid System. Should further information or guidance concerning to the safe use of GO Range actuators be required, it will be provided up on request. Users are also to be familiar with and follow any relevant legislation or statutory provisions regarding health and safety. It is the users responsibility to ensure that the equipment is operated in a safe manner and that any personnel working with or on the equipment are properly trained for the work they are performing and are also aware of their responsibilities related to health and safety in the workplace. It is extremely important that precautions be taken to avoid spark or static discharge in any areas of potentially explosive atmosphere. All Rotork Fluid System actuators are tested prior to despatch. Job specific documentation is shipped with the actuator. Test certificates and replacement documentation are available upon request. The latest general information regarding any Rotork product is available on our website www.rotork.com.

4

S

E

C

T Par. 1. – GO series actuator description

I

O

N

(A)

5

File GO_DESC

GO SERIES ACTUATOR DESCRIPTION

SECTION (A) - Par. 1

GENERAL DESCRIPTION The GO series actuator is gas over oil double acting actuator, fed by pressurized gas. After being filtered, gas flows into the tank through the control valves with respect to the operation (opening or closing) to be performed. Hydraulic oil contained in the tank is pressurized by gas and flows into the respective cylinder chamber, while the oil contained in the other chamber flows into the second tank. The cylinder piston stroke triggers the operation of the actuator. The design characteristics are shown on the data plate attached to the actuator. These actuators are fitted with a hydraulic emergency manual override and operated by means of two hydraulic hand pumps. There are two types of Rotork Fluid System actuators of GO series: the scotch yoke and the rack and pinion series. The main components of these units are the following:

GO scotch yoke series: GO-65; GO-85: GO-100; GO-130; GO-160 GO-161; GO-200; GO-201 GO-270; GO-271

GO rack and pinion series: GO-15; GO-30; GO-60; GO-120; GO-240

A scotch-yoke mechanism (see table DSGA006) which transforms the linear movement of the hydraulic cylinder into a rotary movement suitable to operate quarter turn valves such as ball valves, butterfly valves or plug valves. The scotch-yoke mechanism is included into a perfectly sealed housing, made of welded carbon steel, that protects it against corrosion and that guarantees safety the personnel during the operations. It is also fitted with a guide bar suitable for supporting the transverse forces, to ensure the proper alignment of the piston rod and with bronze sliding blocks and yoke bushing suitable for reducing the friction, to guarantee a long working life. In particular, the guide bar is chromium plated in order to guarantee its protection against corrosion. Hydraulic cylinder (see table DSGE119), made of

carbon steel. The cylinder tube is nickel plated internally, in order to reduce roughness of the surface to a minimum value and to provide highest protection against corrosion. The piston is made of carbon steel with dynamic seals realized in Buna-N and Teflon.

A rack and pinion mechanism (see table DSRA001) which transforms the linear movement of the hydraulic cylinders into a rotary movement suitable to operate quarter turn valves such as ball valves, butterfly valves or plug valves. The rack and pinion mechanism is made of alloy steel and is included into a perfectly sealed housing, made of nodular cast iron, which protects it against corrosion and guarantees safety to the personnel during the operations.

Two opposed hydraulic cylinders (see table DSRE004), made of nodular cast iron. The cylinder tube is nickel plated internally, in order to reduce roughness of the surface to a minimum value and to provide highest protection against corrosion. The relevant piston is made of carbon steel with dynamic seals realized in Buna-N and PTFE.

In both series, there are two mechanical stops to enable the adjustment of the valve angular stroke by means of stop bolts. In case of a scotch yoke type, the stop bolt for the adjustment of the open position of the valve is screwed into the center body closing flange, while the stop bolt for the adjustment of the closed position of the valve is screwed into the bottom flange of the hydraulic cylinder. In case of a rack and pinion type, the stop bolt for the adjustment of the open position of the valve is screwed into the cylinder used to close the valve, while the stop bolt for the adjustment of the closed position of the valve is screwed into the cylinder used to open the valve. In both series, the mechanical visual indicator showing the valve position during the stroke of the actuator

is directly connected to the valve stem. If required, the GO series actuators may also be supplied complete with accessories, such as signalling

limit switches, position transmitter etc.

6

S

E

C Par. 1. - Checks to be carried out upon delivery

T Par. 2. - Storage

I Par. 3. - Safety Considerations

O Par. 4. - Instructions for assembling the actuator onto the valve

N

(B)

7

File CHECK_04

CHECKS TO BE CARRIED OUT UPON DELIVERY

SECTION (B) - Par.1

DAMAGE DURING TRANSPORT Upon delivery, check if the actuator has been damaged during transport and, if necessary, repair the possible damages to the paint-work. DATA PLATE The following information are contained on the actuator data plate: - Serial number. - Tag number. - Model. - Min/max operating pressure. - Order number - Month / year of manufacture. CE MARK: Where applicable, the following plates will be placed, in line with the directives: ATEX 94/9/CE PED 97/23/CE

Please make sure that information printed on the data plate are in conformity with those specified in the order, in the test certificate and in the delivery note. ACCESSORIES When the supply includes accessories, please check if they are in conformity with those listed in the order and in the shipping documents. SETTING OF MECHANICAL STOPS AND LIMIT SWITCHES In the event that the actuator has been delivered already assembled onto the valve, the mechanical stops and electric limit switches (if foreseen) have already been set during assembling. In the event that the actuator has been delivered separately from the valve, the setting of the mechanical stops and electric limit switches (if foreseen), must be carried out after the assembling of the actuator onto the valve according to the instructions stated herein under the applicable paragraph of sections (C) and (D).

8

File STORAGE _01 STORAGE

SECTION (B)-Par.2

GENERAL INSTRUCTIONS The actuators leave the Rotork Fluid System factory in excellent finishing and working conditions, as guaranteed by the inspection certificate issued for each single actuator. In order to keep the actuators in a good condition until they are assembled on the plant, we recommend that the following measures be taken, during the period of storage:

Check if the plugs have been properly assembled on the fluid and electric connections, in order to prevent dust/sand/water from entering during transport and storage.

Actuators awaiting to be assembled onto the valves, must be placed onto wooden pallets, so

as to prevent any damage on the valve coupling flange.

Protect the coupling parts (adapter and coupling joint, flange, etc.) with grease or protective oil.

Keep the actuators in a dry place or provide protection against the direct effect of weather

agents. LONG-TERM STORAGE In case of storage for over 12 months, further operations must be carried out to maintain the actuator in a good working condition, namely:

The actuator must be stroked on a 6-month basis, using filtered, dehydrated and lubricated air in case of pneumatic actuators, or nominated hydraulic mineral oil with NAS 1638 class 6 as minimum cleanliness level in case of hydraulic actuators. Control panel functionality must also be verified. Subsequently, all the threaded connections of the actuator and the control panel are to be carefully closed.

While checking the functionality of the panel and the actuator, examine the electric

connections and terminals to make sure that they are clean and free from oxidation and humidity. Also check the tightness of terminal screws.

The tightness and the functionality of the seals must be checked every 6 months.

All seals must be changed after 3 years of storage.

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File SAFETY_01

SAFETY CONSIDERATIONS

SECTION (E)-Par.3

3.1 MAXIMUM ALLOWABLE TEMPERATURE The maximum temperature allowable for standard build actuators is 100°C (212°F). Other maximum temperature build options are available. It is the responsibility of the user to ensure that the maximum allowable temperature as indicated on the nameplate is not exceeded and also, in the case of sites where a potentially explosive atmosphere may exist, that the surface temperature of the actuator does not exceed the ignition point of the potentially explosive atmosphere. Be aware that the temperature of the contents of the valve/pipeline as well as that of the power supply fluid will affect actuator temperature. A build up of dust or dirt on the actuator can inhibit cooling and contribute to increased surface temperatures. The user should plan and provide for a periodic cleaning/maintenance program that will maintain the installation environment per the guidelines set forth in EN 1127-1 par 6.4.2. 3.2 OPERATING ENVIRONMENT The user must ensure that the operating environment and any materials surrounding the unit cannot lead to a reduction in the safe use of, or the protection afforded by the actuator. Where appropriate, the user must ensure the actuator is suitably protected against its operating environment including, but not limited to, lightning strikes, vibration sources and vehicular movement. If the unit has a nameplate indicating that it is suitable for installation in a potentially explosive atmosphere (hazardous area), it must not be installed in a hazardous area that is not compatible with the gas groups and temperature class defined on the nameplate. 3.3 MECHANICAL CONSIDERATIONS It is recommended that before lifting an actuator onto a valve, great care is taken to ascertain

the position of the valve and orientate the actuator accordingly. Rotork actuators can be mounted on valves in almost any desired position. It is usual however

to align the centreline of the cylinder to the centreline of the associated pipe work. Note: Certain accessory and control components e.g., filter drains, hydraulic reservoirs; require proper orientation with respect to gravity to function properly. Contact Rotork Fluid System if in doubt.

Ensure all fasteners are adequately tightened to avoid loosening during the course of operation, taking into account vibration induced by the dynamics of the pipeline. All tubing used to provide pneumatic/hydraulic power to the actuator must be free from contaminants and debris. Ensure tubing runs are adequately fastened and supported to minimise repetitive stress induced by any vibration induced by the dynamics of the pipeline.

When the actuator has been bolted to the flange or adapter, the position of the stop bolts should be checked to ensure full opening and closing of the valve. If these end of travel positions are not correct, the stop bolts may be adjusted by first loosening the stop nuts and then screwing the bolts in or out until desired end position is obtained. Stroke the yoke away from the stop bolt when adjusting, then return it to check position. When the correct positioning is obtained, re-tighten the stop nuts.

Certain valves incorporate their own stops. In these cases it is recommended that the actuator stop bolt positions coincide with the valve stop positions.

Ensure there are no leaks from any pneumatic or hydraulic connections. Tighten as required. Once in position, the actuator should operate the valve with a smooth continuous action. If

uneven operation occurs, the pneumatic/hydraulic power supply should be checked for correct pressure and volume flow. Flow may be restricted by undersize pipe or fittings. These could throttle the flow thus reducing the pressure and volume at the actuator and causing intermittent motion.

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File GO_ASSY

INSTRUCTIONS FOR ASSEMBLING THE ACTUATOR ONTO THE VALVE

SECTION (B) - Par.4

The assembling of the actuator onto the valve can be performed by: - using the actuator housing flange with threaded holes. - interposing an adapter and a coupling joint. The assembly position of the actuator must be in accordance with plant requirements and with the valve model. In order to assemble the actuator onto the valve, proceed as follows: Make sure that the coupling dimensions of the valve flange and stem meet the actuator coupling

dimensions. Set the valve in the open or closed position, according to the actual position of the actuator. Clean the coupling flange of the valve and remove anything that might prevent a perfect

adherence to the actuator flange. Make sure grease has been perfectly removed. Lubricate the valve stem with oil or grease, to facilitate assembling. Lift the actuator by connecting the sling to the support points of the actuator.

Make sure the sling is suitable for the weight of the actuator. If possible, place the valve stem in a vertical position to facilitate assembling. In this case the actuator must be lifted while the coupling flange is kept in the horizontal position.

Clean the coupling flange of the actuator and remove anything that might prevent a perfect adherence to the valve flange. Make sure grease has been perfectly removed.

If the assembling is carried out by means of a spool piece together with a coupling joint, assemble the latter onto the valve stem before proceeding with the assembling of the actuator.

Lower the actuator onto the valve so that the valve stem slips in the actuator yoke (or in the actuator pinion, on rack and pinion models) or into the groove of the coupling joint, without exercising any force and only with the weight of the actuator. Fasten the actuator to the valve by tightening the nuts of the connecting stud bolts.

If possible, operate the actuator in order to check whether the valve is actuated smoothly.

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S

E

C

T Par. 1. - Setting of angular stroke

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O

N

(C)

12

File GO_AST

SETTING OF ANGULAR STROKE (Scotch yoke actuator series)

SECTION (C)-PAR.1

The angular stroke is set by adjusting the stop bolts which are screwed into the end flange of the hydraulic cylinder and in the housing closing flange. 1 - SETTING OF THE ‘CLOSED VALVE’ POSITION Adjust the stop bolt which is screwed into the end flange of the hydraulic cylinder as follows: 1.1 - Remove the cap nut (item 1). 1.2 - Loosen the lock nut (item 4). 1.3 - Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to

obtain the detachment of the piston (item 6) from the stop bolt (item 2). Screw or unscrew the stop bolt (item 2) and verify, with one closing stroke, the newly obtained angular position. Repeat this operation until the desired angle is obtained. During this operation there will be a small loss of oil through the thread of the stop bolt (item 2).

Note: Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston (item 6), as this may cause fluid pollution. 1.4 - Tighten the fixing nut (item 4). 1.5 - Reassemble the cap nut (item 1). 2 - SETTING OF THE ‘OPEN VALVE’ POSITION Adjust the stop bolt which is screwed into the closing flange of the center body, as follows: 2.1 - Remove the cap nut (item 1). 2.2 - Loosen the lock nut (item 4). 2.3 - Pressurize the hydraulic cylinder (moving the valve towards closing position) in order to obtain

the detachment of the plug for the guide block (item 5) from the stop bolt (item 2). Screw or unscrew the stop bolt (item 2) and verify, with one opening stroke the newly obtained angular position. Repeat this operation until the desired angle is obtained.

2.4 - Tighten the lock nut (item 4). 2.5 - Reassemble the cap nut (item 1). Certain valves incorporate their own stops. For such valves it is recommended that the actuator stop bolt positions coincide with the valve stop position.

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File GO_AST

SETTING OF ANGULAR STROKE (Rack and pinion actuator series)

SECTION (C)-PAR.1

The angular stroke is set by adjusting the stop bolts which are screwed into the hydraulic cylinders. 1 - SETTING OF THE ‘CLOSED VALVE’ POSITION Adjust the stop bolt which is screwed into hydraulic cylinder for open operation as follows: 1.1 - Remove the cap nut (item 1). 1.2 - Loosen the lock nut (item 4). 1.3 - Pressurize the hydraulic cylinder (moving the valve towards the opening position) in order to

obtain the detachment of the piston (item 5) from the stop bolt (item 2). Screw or unscrew the stop bolt (item 2) and verify, with out one closing stroke, the newly obtained angular position. Repeat this operation until the desired angle is obtained. During this operation there will be a small loss of oil through the thread of the stop bolt (item 2).

Note: Attention must be paid so as to avoid direct contact between the stop bolt (item 2) and the piston (item 5), as this may cause fluid pollution. 1.4 - Tighten the fixing nut (item 4). 1.5 - Reassemble the cap nut (item 1). 2 - SETTING OF THE ‘OPEN VALVE’ POSITION Adjust the stop bolt which is screwed into the hydraulic cylinder for close operation, as follows: 2.1 - Remove the cap nut (item 1). 2.2 - Loosen the lock nut (item 4). 2.3 - Pressurize the hydraulic cylinder (moving the valve towards the closing position) in order to

obtain the detachment of the piston (item 5) from the stop bolt (item 2). Screw or unscrew the stop bolt (item 2) and verify, with one opening stroke, the newly obtained angular position. Repeat this operation until the desired angle is obtained. During this operation there will be a small loss of oil through the thread of the stop screw (item 2).

2.4 - Tighten the lock nut (item 4). 2.5 - Reassemble the cap nut (item 1). Certain valves incorporate their own stops. For such valves it is recommended that the actuator stop bolt positions coincide with the valve stop position.

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S

E

C

T Par. 1. - Setting of electric limit switches

I

O

N

(D)

15

File LSW_01 SETTING OF ELECTRIC LIMIT SWITCHES

SECTION (D) - Par. 1

In case the actuator is provided with limit switches their setting should be performed by the user during the actuator testing operations on the valve.

1 - SETTING OF MECHANICALLY OPERATED ELECTRIC LIMIT SWITCHES ASSEMBLED INTO THE LIMIT SWITCHES BOX.

1.1 - SETTING OF THE CLOSING LIMIT SWITCH Place the actuator in the fully closed position of the valve. a.1 Unscrew the four screws (item 1). a.2 Remove the cover (item 2). a.3 Loosen the dowel (item 5) of the cam (item 4), which operates the closing limit switch. a.4 Rotate the cam in order to operate the limit switch. a.5 Tighten the dowel (item 5).

1.2 - SETTING OF THE OPENING LIMIT SWITCH

Place the actuator in the fully open position of the valve. b.1 Loosen the dowel (item 5) of the cam (item 4) which operates the opening limit

switch. b.2 Rotate the cam in order to operate the limit switch. b.3 Tighten the dowel (item 5). b.4 Reassemble the cover (item 2) and screw the four screws (item 1).

NOTE

Should the electric switches box be fitted with a single limit switch, arrange the actuator in the required position of the valve (fully closed or fully open), remove the cover and proceed in line with the above mentioned items a.3 up to a.5 (or b.1 up to b.4). Should the electric switches box be fitted with more than 2 switches, repeat the above operations for all the remaining limit switches.

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File LSW_01 SETTING OF ELECTRIC LIMIT SWITCHES

SECTION (D) - Par. 1

2 - SETTING OF PROXIMITY LIMIT SWITCHES ASSEMBLED INTO THE LIMIT

SWITCHES BOX 2.1 - SETTING OF THE CLOSING LIMIT SWITCH

Place the actuator in the fully closed position of the valve. a.1 Unscrew the four screws (item 1) and remove the cover (item 2). a.2 Loosen the dowel (item 5) of the cam (item 4) which operates the closing electric limit

switch, rotate the cam by placing it on the same axis of the electric limit switch. a.3 In order to adjust the switching point of the electric limit switch, loosen its fixing nuts.

Slide it axially and vary the positioning distance between the electric limit switch and the operating cam. Tighten the fixing nuts.

2.2 - SETTING OF THE OPENING LIMIT SWITCH

Place the actuator in the fully open valve position. b.1 Proceed according to the above mentioned points a.1 and a.3 operating on the cam

and on the opening electric limit switch. b.2 Reassemble the cover (item 2) and screw the four screws (item 1).

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S

E Par. 1. - Arrangement for start-up

C

T Par. 2. - Start-up

I

O Par. 3. – Line break technical information

N

(E)

18

File ARRANGE_GO ARRANGEMENT FOR START-UP

SECTION (E)-Par.1

1.1 MOTIVE POWER SUPPLY Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as

indicated on the nameplate. Verify that medium composition (e.g., filtration, hydration) corresponds to that for which the

actuator was manufactured. Rotork Fluid System must be contacted to verify compatibility of any proposed changes to supply medium.

Ensure that throughout the installation that there are no leaks of a potentially explosive supply medium (e.g., natural gas). Note: Depending upon control circuit design, pneumatically powered actuators may exhaust the power supply gas to atmosphere in the course of normal operation. This may present an unacceptable hazard in some applications. Consult Rotork Fluid System if in doubt as to the suitability of the equipment supplied for your application.

1.2 ACTUATOR / LINE CONNECTIONS Before connecting the actuator to the gas supply line, make sure that pipes and fittings are

according to the applicable plant specifications, in order to guarantee the gas flow required for the operation of the actuator and to avoid that supply pressure drops below the minimum allowable value.

Take every precaution to remove any solid or liquid foreign matter from the pipe work into the actuator, in order to avoid possible damages to the actuator itself or loss of performance. Clean the inside of the pipes used for connection by washing them with suitable detergent and by blowing air into them.

Fasten the piping properly, so as to prevent the loosening of threaded connections, in case the system undergoes strong vibrations.

Once the gas connections have been completed, operate the actuator and check if it works correctly. Also make sure that its operating times are in accordance with those specified in the test certificate and that there aren’t any leakages in the gas/hydraulic connections.

In accordance with the operating diagram, the gas line can be connected to the control panel in the following two ways: 1 Directly to the shuttle valve (item 17).

17: Gas shuttle valve (supply) X1-X2: 1/4 NPT (Female) Gas connections

X2

17

X1

19

File ARRANGE_GO ARRANGEMENT FOR START-UP

SECTION (E)-Par.1

2 Indirectly to the shuttle valve (item17), via 2 isolation filters (items 19) and isolation valves (items16)

16: Isolation valve 17: Gas shuttle valve 19: Filter (supply) X1-X2: 1/4 NPT (Female) Gas connections

The suggested tubing between actuator and main pipe (at user is care) is: O.D. 12 mm rigid tube 1mm thickness, carbon steel/stainless steel, suitable for pressure as per applicable plant specification. In case the control panel is provided with a low pressure sensor (item 23), follow the instructions below:

K: 1/2” NPT (Male) or 1/4" NPT (Female) - Pilot connection

In case the control panel is provided with an adjustable pilot differential (item 27), follow the instructions below:

K1: 1/4" NPT (female) - Pilot gas connection - low

pressure - downstream K2: 1/4" NPT (female) - Pilot gas connection - high

pressure - upstream

K

23

K2K1

27

16 16

X2X1 TO PANEL

17

19 19

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File ARRANGE_GO ARRANGEMENT FOR START-UP

SECTION (E)-Par.1

1.3 ELECTRIC CONNECTIONS The following instructions are applicable to actuators provided with electric accessories (such as limit switches, solenoid valves, etc.). Any electrical connections required are the responsibility of the user. Connection documentation

is supplied with the actuator. Refer to the applicable wiring diagram to identify functions of terminals. Verify that the electrical supply characteristics are compatible with the supplied actuator control components.

Only appropriate certified explosion-proof entry reducers, glands or conduit may be used if the unit is installed in a hazardous area.

Remove any plastic transit plugs. Make cable entries appropriate to the cable type and size.

Ensure that threaded adaptors, cable glands or conduit are tight and fully waterproof. Seal unused cable entries with a steel or brass plug. In hazardous areas an appropriately certified threaded blanking plug must be used. Make sure that the components used for electrical connections (such as cable hose conduits, cable glands) are in accordance with the requirements and codes applicable to the plant, with reference to mechanical and/or explosion-proof protection.

Access to live electrical conductors is forbidden in hazardous areas unless done under a special

permit. Otherwise, all power should be isolated and the unit moved to a non-hazardous area for repair or attention.

The actuator and control components must be protected from electrical sparks, surges, and

lightning strikes as well as magnetic or electro-magnetic fields. This is the responsibility of the user.

Electric connections are to be made by using rigid conduits and trailing cables so as to prevent

anomalous mechanical stresses in the cable entries. Remove the plugs from the cable entries.

Connect the electric feed, control and signal lines to the actuator, by linking them up with the

terminal blocks of electric components in accordance with the applicable wiring diagram. On the unused entries of the pull box, replace the plastic plugs with the metal ones, in order to

guarantee perfect seal and to comply with explosion safety protection codes (where applicable). Once connections have been completed, check if controls and signals work properly.

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File STARTUP GO

START-UP

SECTION (E) - Par.2

During the start-up of the actuator, it is necessary to check if: The oil level in the gas/oil tanks is in accordance with the instructions brought in the “section F”

paragraph 2.

Gas supply pressure, is as prescribed. Feed voltage values of electric components (solenoid valves coils, limit switches, pressure

switches etc., if applicable) are as prescribed.

Actuator controls, such as remote control, local control, emergency control (if applicable), etc. work properly.

The required remote signals (such as valve position, gas supply pressure, etc.) are correct.

The setting of the actuator control unit components is according to the requirements of the plant.

Gas/hydraulic connections show any leakage. If necessary, tighten the nuts of the pipe fittings.

The painted parts have been damaged during transport, assembling or storage operations. Having removed rust, repair the damaged parts following the painting specification.

In case the control panel is provided with a local/remote selector valve (18) may be positioned by means of manual levers located on the poppet valves (4a and 4b) for LOCAL control or by means of the solenoids (5a and 5b) for REMOTE control.

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File linebreak GO

LINE-BREAK TECHNICAL INFORMATION

SECTION (E) - Par.3

INTRODUCTIONS: The Rotork Line-Break system detector (RLD) is designed to close the valves automatically in case pre-determined pressure drop rate is exceeded, in order to prevent gas leakage due to pipeline breaking. Under normal working conditions, gas pressure will be steady or it will slowly change due to many factors (e.g. increase/decrease of gas users). In case of pipeline break down, the variation of pressure drop will depend on the absolute pressure, the gas density, the dimensions and the type of failure, the pipe line dimensions, the location of the failure (upstream or downstream) and the distance from the break (i.e. the greater the distance the lower the speed). Therefore, Line-break devices ought to be easily regulated to meet different working conditions and all the characteristics of the line. A compromise must also be made in adjusting the pressure drop speed setpoint. In fact, it must be as low as possible to detect remote failures, but not too close to the normal variation of the pipeline pressure, as the line would have to be closed. FUNCTIONALITY DESCRIPTION: Due to the fact that many Line-break detectors (RLD) have been mounted as a protection on the gasline , they are placed in countryside areas, far away from stations and cities. They need to have their own source of energy, directly from the line pressure. The RLD system (see the control schematic) includes the followings components: reference tank (33), adjustable differential pressure switch (40), 3/2 pilot manual reset valve (41), check valve (35), calibrated orifice (36), gauges (10) filters (32-37) and stop valves (31-34). The RLD has to be connected to the pipeline downstream from the main valve so as to avoid undesirable closing operations during the opening of the valve because pressure drops quickly in the upstream line during this operation.

40

41

34

35

37

32

36

10

23

File linebreak GO

LINE-BREAK TECHNICAL INFORMATION

SECTION (E) - Par.3

The connection coming from the gasline can be intercepted using a stop valve (34) and the gas is filtered (37). When pipeline pressure rises, gas flows through the check valve (35) and orifice (36), into the reference tank (33). When pressure falls, it remains higher in the tank than in the line because the check valve closes and the gas flows back into the pipeline through the orifice only. This orifice restrictor creates a differential pressure (∆P) that acts upon the adj. pressure switch (40) if it exceeds the adjusted value. The pressure switch acts upon the valve (Item 41) which permits the closing of the main valve. In order to open the main valve again, once normal conditions have been re-established, it is necessary to reset the valve (41) with the relevant manual reset. The faster the drop rate in the pipeline, the smaller the orifice, the bigger the volume of the rate tank and the lower the absolute pressure the greater the differential pressure (∆P) across the diaphragm valve. When pressure starts to drop due to a pipeline break down, the ∆P takes time to reach its maximum value. The time elapsed depends on the diameter of the calibrated orifice, the absolute pressure in the line and the pressure drop speed: the smaller the orifice, the lower the line pressure and the greater the drop rate, the longer the time required to reach the maximum value of differential pressure. The value of the ∆P for the operation of the adj. pressure switch valve can be adjusted within the range from 0.2 up to 4 Barg by rotating the relevant pommel nut referring to the indicator scale. As differential pressure needs to be limited within the selected range, it is necessary to use the 0.4 mm diameter calibrated orifice hole for the lower values of pressure drop speed at a high value of working pressure, or the 0.8 mm diameter calibrate orifice hole, for the higher value of pressure drop speed at low working pressure. FIGURE 1 Curves related to maximum ∆P acting upon the pressure switch at differential initial pressure and at differential pressure drop rate, with the 0.4mm orifice.

ORIFICE 0.4 mm (Time from 2 up to 8 minutes)

00,250,5

0,751

1,251,5

1,752

2,252,5

2,753

3,253,5

3,754

4,25

0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1 1,2 1,3 1,4 1,5 1,6 1,7 1,8 1,9

Pressure Drop Speed ( Bar / min )

∆P

( Bar

) fo

r NA

TUR

AL

GA

S at

20

°C

Pres. 25 Bar

Pres. 35 Bar

Pres. 45 Bar

Pres. 55 Bar

Pres. 65 Bar

Pres. 75 Bar

Pres. 85 Bar

FIGURE 1

The ∆P is obtained within the maximum time of 480 seconds for Natural Gas at 20 °C.

24

File linebreak GO

LINE-BREAK TECHNICAL INFORMATION

SECTION (E) - Par.3

FIGURE 2 Curves related to maximum ∆P acting upon the diaphragm valve at differential initial pressure and at differential pressure drop rate, with the 0.8mm orifice.

ORIFICE 0.8 mm (Time from 1 up to 4 minutes )

0

0,25

0,5

0,75

1

1,25

1,5

1,75

2

2,25

2,5

2,75

3

3,25

3,5

3,75

4

4,25

0 0,25 0,5 0,75 1 1,25 1,5 1,75 2 2,25 2,5 2,75 3 3,25 3,5 3,75 4 4,25

Pressure Drop Speed ( Bar / min )

∆P

( Bar

) fo

r NA

TUR

AL

GA

S at

20

°C

Pres. 25 Bar

Pres. 35 Bar

Pres. 45 Bar

Pres. 55 Bar

Pres. 65 Bar

Pres. 75 Bar

Pres. 85 Bar

FIGURE 2

The ∆P is obtained within the maximum time of 240 seconds for Natural Gas at 20 °C. CALIBRATION AND SETTING OF LINE-BREAK DEVICE: To carry out the setting and calibration of the Line-break device, it necessary to know: - the variation range of working pressure. - the pressure drop speed at minimum working pressure. The minimum working pressure has been

chosen to prevent undesired line break interventions (in fact at this time the ∆P is higher than at maximum working pressure). Use of Calibration charts (Figures 1 & 2) to find the correct orifice and the ∆P: find the specified drop rate along the horizontal axis and trace a line upward to where it intersects the specified minimum working pressure. From this intersection trace a horizontal line to the vertical axis and read the ∆P value. To carry out the setting on the diaphragm valve, remove the cover, unscrew the “5.5 mm” hexagonal screw and rotate the pommel nut on the top, referring to the graded scale indicator. up to the desirable value, To change the calibrated orifice (36), first make sure that the system is depressurised. Then remove the cap by means of “17 mm” Allen key and then the second screw inside the block by means of a “8 mm” Allen key. Now, screw the replacing orifice tightly by means of a “8 mm” Allen key and screw back the cap screw tightly using the “17 mm” Allen key. Ensure that all connections are leak tight and check with soapy water when the system is pressurized

25

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C

T Par. 1. - Maintenance

I

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(F)

26

File MAINT_GO MAINTENANCE

SECTION (F) - Par.1

Rotork actuators are designed to work for long periods of time under severe conditions. However, a preventive approach to maintenance helps prevent costly down time and can actually reduce the cost of ownership. Rotork can provide actuator maintenance contracts tailored to meet each individual customer’s requirements. Any personnel working with or on the equipment must be properly trained for the work they are performing and aware of their responsibilities relating to health and safety in the workplace. No inspection or repair should be undertaken unless it conforms with applicable hazardous area certification requirements. Under no circumstances should any modification or alteration be carried out on the unit as this could invalidate the certification. Before performing maintenance, the actuator should be isolated from remote control signals and pneumatic/hydraulic power supply. The system should then be relieved of any internal pressure prior to disassembly. Improper operation, adjustment or maintenance of the actuator and controls may, depending on the application, release potentially explosive gases and / or dangerous liquids. After maintenance has been performed and re-assembly completed, follow the inspection guidelines as outlined below: PERIODIC INSPECTION Ensure that the actuator operates the valve correctly within the required cycle time. The actuator should be cycled several times with all the existing controls e.g., remote control, local control and manual override, particularly if the actuator is not operated frequently enough. Verify that the power fluid supply pressure value is within the required range. Visually inspect the external components of the actuator for physical damage. Check pneumatic/hydraulic connections for leaks. Tighten pipe fittings as required. Remove build-up dust and dirt from all actuator surfaces. They can inhibit cooling and thus raise the temperature above the maximum allowable limit. Inspect actuator paint work for damages to ensure continued corrosion protection. Touch-up as required in accordance to applicable paint specification INSTRUCTIONS FOR CHANGING OIL IN THE TANKS AND IN THE HYDRAULIC CIRCUIT.

Rotork Fluid System recommends to change hydraulic oil at 6-year or 20000-operations intervals. Proceed as follows: Place the actuator in the close position. Close the isolation valves (16). Operate with the valves (4A and 4B) so as to drain the gas from the circuit. If there is a storage tank in the circuit, use the drain valve to drain the gas. Unscrew the plugs (P7 & P8) and discharge the oil from the tanks. Unscrew the plugs (P5 & P6) and discharge the oil from the cylinder. Reassemble the plugs and fill the tanks in accordance with the instructions brought in this section, paragraph 2.

P5P6

P7

P8

16164B

4A

27

File FILL_GO GAS / OIL TANKS OIL FILLING INSTRUCTIONS

AND HYDRAULIC CIRCUIT PURGE

SECTION (F) - Par.2

The following instructions prescribe the procedure for filling the gas/oil tanks of the GO series actuator.

This operation should precede the assembling of the actuator on to the valve and the connecting of the gas supply line, as described below: Actuators have been sent by Rotork Fluid

System set in the close position; this setting can be checked through the position indicator displayed on the carter cover or on the microswitches box, (if applicable).

Unscrew and remove the plug (P3), with the respective dipstick.

Fill the tank (26.1) with oil to the max level of the dipstick.

Place the 3-way hand operated valve (28A1) in the “manual” position.

Unscrew the drain plug (P1). Start pumping (28B1) until oil spills out from the

hole of the drain plug (P1); close the drain plug. Always acting with the pump (28B1), take the

actuator in the completely open position. Place the 3-way hand operated valve (28A1) in

the “remote” position. Unscrew and remove the plug (P4), with the

respective dipstick. Fill the tank (26.2) with oil to the max level of

the dipstick. Place the 3-way hand operated valve (28A2) in

the “manual” position. Unscrew the drain plug (P2). Start pumping (28B2) until oil spills out from the

hole of the drain plug (P2); close the drain plug. Always acting with the pump (28B2) take the

actuator in the complete close position. Check the oil level in the tank (26.1) using a

dipstick, if necessary refill to max level. Screw the plugs (P3). Place the 3-way hand-operated valve (28A2) in

the “remote” position and the valve (28A1) in the “manual” position.

Using the pump (28B1) set the actuator in the completely open position.

Check the oil level in the tank (26.2) using dipstick, if necessary refill to max level.

Screw the plugs (item P4). Place the 3-way hand operated valves (28A1)

in the “remote” position. The actuator is now ready to be assembled to the valve and connected to the gas supply line.

P4 P3

26.2

26.1

P2 P1

28A1

28B2

28A2

28B1

28

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C Par. 1. - Replacement of cylinder seals

T

I

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(G)

29

File GO_SEAL

REPLACEMENT OF CYLINDER SEALS (scotch yoke series)

SECTION (G) - Par.1

When cylinder seals need to be replaced, due to a leakage or for scheduled preventive maintenance, proceed as described here below (See tables DSGA006 and DSGE119): This procedure is applicable after making sure that pneumatic/hydraulic pressure and electrical power have been removed from the actuator.

- Disconnect the hydraulic supply tubes from the cylinder head and bottom flanges.

PHASE 1-DISASSEMBLY 1.1 - CENTER BODY (See table DSGA006)

- Unscrew the bolts (17). - Remove the cover (22), screwing 2 screws

in the appropriate thread holes on the cover to facilitate the removing operation.

- Loosen the dowel (item 4).

1.2 - HYDRAULIC CYLINDER (See table DSGE119)

- Unscrew the nuts (17). - Remove the end flange (13). - Remove the cylinder tube (7). - Unscrew the piston rod (6) from the guide

block (table A item 7) and slide it off. - Unscrew the screws (2). - Remove the head flange (4).

PHASE 2-SEALS REPLACEMNT - Remove the o-rings (12 ; 21) the back-up

rings (23 ;24), the piston gasket (10), the sliding rings (9) and the gaskets (1 & 5). Carefully clean the respective grooves. Make sure that the cylinder components are in a good condition and clean. Replace all the above mentioned seals and lubricate them with a grease film.

HYDRAULIC CYLINDER (Table DSGE119)

CENTER BODY (Table DSGA006)

30

File GO_SEAL

REPLACEMENT OF CYLINDER SEALS (scotch yoke series)

SECTION (G) - Par.1

PHASE 3 REASSEMBLY 3.1 - HYDRAULIC CYLINDER (See table

DSGE119)

Taking care not to damage the seals proceed with the reassembling as follows:

- Reassemble the head flange (4) and screw the bolts (2) to the recommended torque (see table), alternating between opposite corners.

- Reassemble the piston rod (6) by screwing it in onto the guide block (See table A item 7).

- Tighten the dowel (table A item 4). - Reassemble the cylinder tube (7). - Reassemble the end flange (13). - Tighten the nuts (17) to the recommended

torque (see table), alternating between opposite corners.

3.2 - CENTER BODY (See table A) - Check if the cover gasket (13) is in a good

condition, otherwise replace it. - Reassemble the cover (22) using the

parallel pin reference. - Screw the bolts ( 17) to the recommended

torque (see table), alternating between opposite corners.

- Connect the oil supply tubes to the cylinder end and head flanges.

- Carry out a few operations with the actuator in order to check if the movement is regular and if there are leakages through the seals.

- If necessary, reset the angular stroke in accordance with the instructions in section “C”.Check if the painted parts have been damaged during the disassembly and reassembly. If necessary repaint them in accordance with the applicable painting specifications.

HYDRAULIC CYLINDER (Table DSGE119)

CENTER BODY (Table DSGA006)

RECOMMENDED

TIGHTENING TORQUE

Bolt size NM FT. LBS M6 8.5 6 M8 20 15

M10 40 30 M12 55 40 M14 110 81 M16 220 162 M20 430 317 M22 425 313 M24 585 431 M27 785 579 M30 1250 921 M33 1400 1030 M36 1750 1290

31

File GO_SEAL

REPLACEMENT OF CYLINDER SEALS (rack and pinion series)

SECTION (G) - Par.2

PHASE 1-DISASSEMBLY - Disconnect the hydraulic supply tube from the

cylinder. - Unscrew the screw (2). - Remove the cylinder (10).

PHASE 2-SEALS REPLACEMENT - Remove the piston gasket (8),

the sliding rings (9) and the o-ring (11). - Carefully clean the relative grooves. - Make sure that the cylinder components are in a good condition and clean. Replace all the above mentioned seals and lubricate them with a grease film.

PHASE 3-REASSEMBLY Taking care not to damage the seals, proceed with the reassembling in the following way.

- Reassemble the cylinder tube (10). - Tighten the screw (2) to the recommended torque (see table) alternating between opposite corners.

- Connect the hydraulic supply tube to the cylinder.

- Carry out a few operations with the actuator in order to check if the movement is regular and if there are any leakages through the seals. Check if the painted parts have been damaged during disassembly and/or reassembly. If necessary repaint them in accordance with the applicable painting specifications.

HYDRAULIC CYLINDER (Table DSRE004)

RECOMMENDED TIGHTENING TORQUE

Bolt size NM FT. LBS M6 8.5 6 M8 20 15

M10 40 30 M12 55 40 M14 110 81 M16 220 162 M20 430 317 M22 425 313 M24 585 431 M27 785 579 M30 1250 921 M33 1400 1030 M36 1750 1290

32

S

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C Par. 1 - Lubrication

T Par. 2 - Hydraulic oil features

I

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(H)

33

File GREASE

LUBRICATION

SECTION (H) - Par.1

In general, there is no need to lubricate the actuator because its mechanism is lubricated-for life. The following greases are used by Rotork Fluid System to lubricate the mechanical components and they are recommended for a possible lubrication: GREASE FOR GO SCOTCH YOKE SERIES

MANUFACTURER: MOBIL

TRADE NAME: MOBILTEMP 78

COLOR: GRAY/BLACK

SOAP TYPE: INORGANIC

OIL TYPE: MINERAL

CONSISTENCY (NLGI GRADE)-ASTM D217: 1

WORKED PENETRATION AT 25°C-ASTM D217: 295/325 dmm

DROPPING POINT-ASTM D2265 260°C

VISCOSITY OF BASE OIL AT 40°C-ASTM D445: 485 cSt

VISCOSITY OF BASE OIL AT 100°C-ASTM D445: 32 cSt GREASE FOR GO RACK AND PINION SERIES

MANUFACTURER: TEXACO

TRADE NAME: GREASE L00

COLOR: DARK BROWN

CONSISTENCY NLGI-ASTM D217: 00

LITHIUM SOAP: 6%

DROPPING POINT-ASTM D566: 180°C

BASE OIL FLASH POINT-ASTM D92: 220°C

OIL SEPARATION-DIN 51817: 2% MAX

OPERATING TEMPERATURE: -30°/+110°C Note: The above described grease types is the Rotork Fluid System standard for lubrication of scotch yoke and rack and pinion actuators. In case a different grease type is requested, refer to the type described in the Instructions Manual.

34

File HYDROIL_03 HYDRAULIC OIL FEATURES

SECTION (H) - Par.2

MANUFACTURER: MOBIL

TRADE NAME: DTE 11

VISCOSITY AT 40°C: 16,5 cSt

VISCOSITY AT 100°C: 4,2 cSt

VISCOSITY INDEX ASTM: 168

ISO GRADE: 16

POUR POINT: -42 °C

SPECIFIC WEIGHT AT 15°C: 0,85 kg/dm3

Note: The above described oil type is the Rotork Fluid System standard. In case a different oil type is requested, refer to the type described in the Instruction Manual.

35

S

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C

T Par. 1 - Typical sectional drawings with parts-list

I

O

N

(I)

36

37

38

39

40

41

42

S

E

C

T Par. 1 - Instructions for actuator lifting

I

O

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(L)

43

44

S

E

C

T Par. 1 – Operating instructions for electric control systems

I Par. 2 – Features of the Rotork limit switch box type MB1

O

N

(M)

45

OPERATING INSTRUCTIONS FOR ELECTRIC CONTROL SYSTEMS

SECTION (M) - Par.1

In case the actuator is provided with an electric control system, the setting is performed by Rotork Fluid System during actuator testing operations. For the start-up and should it be necessary to re-set the electric components, please proceed as described here below:

WARNING

• DO NOT OPEN ELECTRIC COMPONENTS UNDER VOLTAGE!

• CHECK THE ELECTRIC EARTH BEFORE OPERATING ELECTRIC COMPONENTS!

• REFER TO THE MANUFACTURER USER GUIDE FOR THE CORRECT USE OF ELECTRIC COMPONENTS.

46

OPERATING INSTRUCTIONS FOR ELECTRIC CONTROL SYSTEMS

SECTION (M) - Par.1

Purpose of these instructions During work in explosive environments, the safety of the people and the plant depends on the adherence to all safety regulations. Assembling and maintenance staff therefore bear particular responsibility. The prerequisite is a thorough knowledge and understanding of the rules and regulations in place. These introductions give a brief summary of the most important safety measures and regulations to be observed by the staff.

Safety instructions Observe the following during setting-up and operation:

• National safety regulations.

• National accident prevention regulations.

• Safety guidelines contained herein.

• Characteristic values on the rating and data plates.

• Test certificates and special conditions outlined in them.

Conversions and modifications to equipment which might impair explosion protection are not allowed. The equipment may be operated only if undamaged and clean.

Installation and operation The following must be observed with regards to setting up and operating the explosion-proof equipment:

• National safety regulations

• National equipment safety legislation

• National installation regulations

• Generally recognized technical regulations

This equipment may be transported and stored only in its original packaging. Damages neutralize explosion safety.

Technical data Refer to the technical data on the rating plate on each control component or to the manufacture user guide.

Conformity to standards Controls are state of the art. They have been developed, manufactured and inspected in accordance with ISO 9001.

47

ROTORK LIMIT SWITCH BOX TYPE MB1

SECTION (M) - Par.2

FEATURES

• Electric protection EEx d IIC T6 • Mechanical protection IP67 • MAX voltage 250 V • MAX current 25 A • Nominal frequency 50/60 Hz • Tested according to EN 50.014 and EN 50.018

The ROTORK limit switch enclosure can contain electric limit switches and terminal boards where switches wires are connected according as required by the customer. The external cable connection to terminals is at user’s care.

MICROSWITCHES

TYPE VOLTAGE RESISTIVE LOAD INDUCTIVE LOAD MANUFACTURER250 V.c.c. 0.5 A 0.25 A M2 250 V.a.c. 15 A 15 A

BURGESS

250 V.c.c. 0.5 A 0.25 A K5 250 V.a.c. 25 A 15 A

BURGESS

250 V.c.c. 0.25 A 0.03 A VCF 250 V.a.c. 10 A 10 A

BURGESS

250 V.c.c. 0.25 A 0.03 A V37YR 250 V.a.c. 5 A 10 A

BURGESS

28 V.c.c. 25 A 10 A 1HS3 115 V.a.c. 1 A 1 A

HONEYWELL

BZ-2RW8227 2551-A2 125 V.a.c. 1 A 1 A HONEYWELL

250 V.c.c. 0.25 A 0.25 A Z 15GW22 250 V.a.c. 15 A 15 A

OMRON

TERMINALS TYPE VOLTAGE NOMINAL

CURRENT SECTION mm2 MANUFACTURER

MK3 380 V 25A 2.5 WEIDMULLER AKZ 1.5 250 V 18A 1.5 WEIDMULLER SAK 2.5 750 V 26A 2.5 WEIDMULLER

MK3 380 V 25A 2.5 WEIDMULLER AKZ 1.5 250 V 18A 1.5 WEIDMULLER SAK 2.5 750 V 26A 2.5 WEIDMULLER

IMPORTANT NOTICE: Before operating any of the above electric components, see section (M) - Par.1