AUMA GSTI Series Bedienungsanleitung

Multi-turn gearbox

GSTI 25.1 – GSTI 40.1

qualified for use in nuclear power plants

(Inside and Outside Containment)

Operation instructions Assembly, operation, commissioning

Table of contents

1. Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.1. Range of application 3

1.2. Maintenance 3

1.3. Warnings and notes 3

2. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3. Transport, storage and packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3.1. Transport 5

3.2. Storage 5

3.3. Packaging 5

4. Handwheel fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5. Mounting multi-turn actuators SAI and SAN . . . . . . . . . . . . . . . . . . . . . . 6

6. Mounting to valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

7. Operation of valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

8. Enclosure protection IP 68-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

9.1. General references 13

9.2. Change of grease 14

10. Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

11. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

12. Spare parts list spur gearboxes GSTI 25.1 – GSTI 40.1 . . . . . . . . . . . . . . . 16

13. Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

13.1. Certificate of type testing 18

13.2. Declaration of incorporation 19

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

(Inside and Outside Containment) Operation instructions

Read the operation instructions first

.Observe safety instructions.

.These operation instructions are part of the product.

.Store operation instructions during product life.

.Pass on instructions to any subsequent user or owner of the product.

1. Safety instructions

1.1. Range of application

AUMA spur gearboxes GSTI 25.1 – GSTI 40.1 are used for the operation of

valves (e.g.gate valves and globe valves).

They are qualified for use in nuclear power plants inside and outside

containment. They are designed for manual operation as well as motor oper-

ation in conjunction with electric actuators.

As the case may be, deviations from the qualified versions may exist for

these products.These deviations have been discussed and agreed between

customer and manufacturer (AUMA).

Deviating versions are stipulated in the order acknowledgement and may be

enquired from AUMA stating the commission number (refer to the name

plate). Before using the product, check whether the respective service

conditions match those of the version contractually stipulated in the order

acknowledgement.

For other applications, please consult AUMA.The manufacturer is not liable

for any possible damage resulting from use in other than the designated

applications.Such risk lies entirely with the user.

Observance of these operation instructions is considered as part of the

designated use.

1.2. Maintenance

The maintenance instructions (refer to page 13) must be observed, other-

wise a safe operation of the spur gearbox is no longer guaranteed.

1.3. Warnings and notes

Failure to observe the warnings and notes may lead to serious injuries or

damage.Qualified personnel must be thoroughly familiar with all warnings

and notes in these operation instructions.

Correct transport, proper storage, mounting and installation, as well as

careful commissioning are essential to ensure a trouble-free and safe oper-

ation.

The following references draw special attention to safety-relevant proce-

dures in these operation instructions.Each is marked by the appropriate

pictograph.

This pictograph means: Note!

“Note” marks activities or procedures which have major influence on the

correct operation.Non-observance of these notes may lead to consequen-

tial damage.

This pictograph means: Warning!

“Warning” marks activities or procedures which, if not carried out correctly,

can affect the safety of persons or material.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

Operation instructions (Inside and Outside Containment)

2. Technical data

Qualification

According to IEEE 382-1996.

Application

For motor operation or manual operation of valves (e.g. gate valves and globe valves) in nuclear power plants for inside and

outside containment in compliance with IEEE 381-1996

Features and functions

Type of duty Open-close duty: Short-time duty S2 - 15 min.

Restriction for GSTI 40.1 max. input speed ≤90 rpm

Direction of rotation Clockwise rotation at input shaft results in clockwise rotation at output shaft

Stages Double stage

Input shaft GSTI 25.1 – GSTI 40.1: For standard reduction ratios, the input shaft is made of stainless steel.

Exception: GSTI 40.1 22 : 1 and 16 : 1

Standard: Cylindrical with parallel key according to DIN 6885.1

Output torques

Operation

Motor operation Directly via electric multi-turn actuator

Flanges for mounting the multi-turn actuator, also refer to separate Technical data sheets.

Manual operation Directly via handwheel (not qualified)

Valve attachment

Mounting position Any position

Output drive types A, B1, B2, B3, B4 according to EN ISO 5210

A, B, E according to DIN 3210

Special output drive: AF

Service conditions

Enclosure protection EN 60529 IP 68-6 dust and water tight up to max. 6 m head of water.

Type-tested with 5.0 bar overpressure (with air) (also refer to page 12)

Corrosion protection KI, aluminium-free version in combination with multi-turn actuator SAI (Inside Containment)

and in combination with multi-turn actuator SAN (Outside Containment)

Finish coating Decontaminable

Colour Standard: Silver-grey (RAL 7001)

Option: Other colours are possible on request

Ambient temperature Standard: –25 °C to +80 °C,

DBE conditions for a short time up to +185 °C

Lifetime Open-close duty: 5,000 operating cycles with load profile accroding to KTA 3504-9/88

Further information

Reference documents Product description Spur gearboxes GSTI 25.1 – GSTI 40.1

Dimensions GSTI 25.1 – GSTI 40.1

Technical data GSTI 25.1 – GSTI 40.1

Technical data SAI/SAN

Drawings indicating centre of gravity GSTI3)

1) At max. output torque

2) Conversion factor for output torque to input torque

3) Note the permissible actuator weight and the centre of gravity of the actuator-gearbox combination.

For actuators by other manufacturers, please contact AUMA.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

(Inside and Outside Containment) Operation instructions

Type Output torque Reduction ratio Input torque1) Factor2)

max. Nm Nm

GSTI 25.1 2,000 4 : 1 556 3.6

5.6 : 1 397 5.0

8 : 1 278 7.2

GSTI 30.1 4,000 5.6 : 1 794 5.0

8 : 1 556 7.2

11 : 1 404 9.9

GSTI 35.1 8,000 8 : 1 1,111 7.2

11 : 1 808 9.9

16 : 1 556 14.4

GSTI 40.1 16,000 11 : 1 1,616 9.9

16 : 1 1,111 14.4

22 : 1 808 19.8

Type GSTI 25.1 GSTI 30.1 GSTI 35.1 GSTI 40.1

Handwheelmm 500 500 500 500

3. Transport, storage and packaging

3.1. Transport .Transport to place of installation in sturdy packing.

.If mounted together with actuator:

Attach ropes or hooks for the purpose of lifting by hoist only to the

gearbox and not to the actuator.

3.2. Storage .Store in well-ventilated, dry room.

.Protect against floor dampness by storage on a shelf or on a

wooden pallet.

.Cover to protect against dust and dirt.

.Apply suitable corrosion protection agent to uncoated surfaces.

In case gearboxes are to be stored for a long period (more than 6 months),

the following points must be observed additionally:

.Prior to storage: Protect uncoated surfaces, in particular the output drive

parts and mounting surface, with long-term corrosion protection agent.

.Check for corrosion approximately every 6 months. If first signs of corro-

sion show, apply new corrosion protection.

3.3. Packaging

Our products are protected by special packaging for the transport ex works.

The packaging consists of environmentally friendly materials which can

easily be separated and recycled.

For the disposal of the packaging material, we recommend recycling and

collection centres.

We use the following packaging materials:

Wooden material boards (OSB)/cardboard/paper/PE film

4. Handwheel fitting

For gearboxes designed for manual operation, the handwheel is supplied

separately.Fitting is done on site according to figure 1.

The handwheel has not been submitted to any seismic test and is therefore

not qualified according to IEEE.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

Operation instructions (Inside and Outside Containment)

Figure 1: Handwheel Ball handle

(option)

Spacer

(partly required)

Circlip

Handwheel

Gearbox worm shaft

Circlip

Spacer

(partly required)

5. Mounting multi-turn actuators SAI and SAN

Mounting multi-turn actuators to gearboxes is described in the operation

instructions pertaining to the multi-turn actuator.

Mounting the multi-turn actuator:

.Thoroughly degrease the faces of the bearing flange at actuator and of the

input flange at spur gearbox.

.Place the multi-turn actuator on the spur gearbox.

.Ensure that the spigot mates uniformly in the recess and that the mounting

faces are in complete contact.

.Fasten actuator with screws and lock washers (see table 1) at the flange

of the spur gearbox.

.Fasten screws crosswise with a torque according to table 2.

Do not attach ropes or hooks for the purpose of lifting the

actuator by hoist to the handwheel. If multi-turn actuator is

mounted on gearbox, attach ropes or hooks for the purpose

of lifting by hoist to gearbox and not to multi-turn actuator.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

(Inside and Outside Containment) Operation instructions

Figure 2: Mounting multi-turn actuators onto spur gearboxes

Input flange

Bearing flange

Gearboxes SAI 50-F14/G1/2

SAN 14.5-F14/G1/2

SAI 100-F16/G3

SAN 16.1-F16/G3

SAN 25.1-F25/G4

Screw Pcs. Screw Pcs. Screw Pcs.

GSTI 25.1 M16 x 40 4 – –

GSTI 30.1 M16 x 40 4 M20 x 50 4 –

GSTI 35.1 M16 x 40 4 M20 x 50 4 –

GSTI 40.1 – M20 x 50 4 M 16 x 50 8

Table 1: Screws for mounting AUMA multi-turn actuators onto spur gearboxes

Screws for actuator

For mounting AUMA devices, screws are supplied together with the gear-

boxes. When mounting other devices, the screws might be either too long or

too short (insufficient reach of screw).

Danger of falling devices due to fracturing when using inap-

propriate screws.

Death or serious injury possible!

Check length of screws.

The depth of screws must be sufficient for the internal threads to ensure the

supporting strength of the device and to adopt the lateral forces due to the

applied torque.

Screws which are too long could make contact with the housing parts.This

causes a risk that the device could shift radially with respect to the gearbox.

This can lead to shearing off the screws.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

Operation instructions (Inside and Outside Containment)

6. Mounting to valve

The gearboxes can be operated in any mounting position.

.Prior to mounting, the gearbox must be checked for dam-

age. Damaged parts must be replaced by original spare

parts.

.After mounting to valve, touch up any possible damage to

paint finish.

Mount gearbox to valve (with output drive types B1 – B4 or E)

.Check whether mounting flanges match.

.Check whether bore and keyway match the input shaft of the valve.

.Apply a small quantity of grease to input shaft of valve..

.Fit gearbox.

Information: Ensure that the spigot fits uniformly in the recess and

that the mounting faces are in complete contact

.Fasten with screws of minimum quality 8.8 according to table 2.

Information: We recommend applying liquid thread sealing material to

the screws to avoid contact corrosion.

.Fasten screws crosswise to a torque according to table 2.

Anschlussform A

Anwendung:

.Anschlussform für steigende, nicht drehende Spindel

.Zur Aufnahme von Schubkräften geeignet

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

(Inside and Outside Containment) Operation instructions

Figure 3

Output drive type B1/B2

Plug sleeve Output drive type B3/B4

Bore with keyway

Screws Fastening torque TA[Nm]

Thread Strength class

8.8 A2-80/A4-80 10.9

M16 214 200 314

M20 431 392 615

M30 1,489 – 2,121

M36 2,594 – 3,695

Table 2: Fastening torques for screws

Output drive type A

Application:

.Output drive for rising, non-rotating valve stem

.Suitable for accepting thrust

Finish machining of stem nut

This working stop is only required if stem nut is supplied unbored or with pilot bore.

The output drive flange does not have to be removed from the gearbox.

.Remove spigot ring (80.2, figure ) from output drive.

.Remove stem nut (80.3) together with bearings (80.01 and 80.02).

.Remove bearing races (80.02) and bearing rims (80.01) from stem nut (80.3).

.Bore and drill stem nut (80.03) and cut thread.

Information: When fixing in the chuck, make sure stem nut runs true!

.Clean the machined stem nut (80.3).

.Apply sufficient Lithium soap EP multi-purpose grease to bearing rims

(80.01) and bearing races (80.02) ensuring that all hollow spaces are

filled with grease.

.Place greased bearing rims (80.1) and bearing races (80.02) on stem nut (80.3).

.Re-insert stem nut (80.3) with bearings (80.01 and 80.02) into output drive.

Information: Ensure that dogs or splines are placed correctly in the

keyway of the hollow shaft.

.Screw in spigot ring (80.2) until it is firm against the shoulder.

Mount gearbox (with output drive type A) to valve

[1] Valve stem

[2] Output drive type A

[3] Screws to actuator

[4] Valve flange

[5] Screws to output drive

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

Operation instructions (Inside and Outside Containment)

Figure 4

80.3

80.2

Output drive type A

Stem nut

80.01/80.02

Figure 5

.If the output drive type A is already mounted to the gearbox: Loosen

screws [3] and remove output drive type A [2].

.Check if the flange of output drive type A matches the valve flange [4].

.Apply a small quantity of grease to the valve stem [1].

.Place output drive type A on the valve stem and turn until it is flush on the

valve flange.

.Turn output drive type A until alignment of the fixing holes.

.Screw in fastening screws [5], however do not completely tighten.

.Fit gearbox on the valve stem so that the stem nut dogs engage into the

output socket.

The flanges are flush with each other if properly engaged.

.Adjust gearbox until alignment of the fixing holes.

.Fasten gearbox with screws [3].

.Fasten screws [3] crosswise with a torque according to table 2.

.Turn gearbox and actuator with handwheel in direction OPEN until valve

flange and output drive type A are firmly placed together.

.Tighten fastening screws [5] between valve and output drive type A

crosswise applying a torque according to table 2.

Protection tube for rising valve stem

.Seal thread of protection tube with hemp, Teflon tape, or thread sealing

material.

.Screw protection tube (1) into thread (figure 6) and tighten it firmly.

.Push down the sealing (2) to the housing.

.Check whether cap (3) is available and without damage.

Multi-turn gearbox GSTI 25.1 – GSTI 40.1 qualified for use in nuclear power plants

(Inside and Outside Containment) Operation instructions

Figure 6: Protection tube for rising valve stem

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