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BIFFI ALGAS-MHP Installation, Operation And Maintenance Manual

Spring-return pneumatic actuator with hydraulic handpump
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Biffi ALGAS-MHP
Spring-Return Pneumatic Actuator with Hydraulic Handpump
Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center:
Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it
Installation, Operation and Maintenance Manual
MAN 689 Rev. 6
June 2021

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  • Page 1 Spring-Return Pneumatic Actuator with Hydraulic Handpump Copyright © Biffi. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.biffi.it or from your nearest Biffi Center: Biffi Italia s.r.l. - Strada Biffi 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Revision Details Installation, Operation and Maintenance Manual MAN 689 Rev. 6 June 2021 Revision Details Rev. Date Description Prepared Checked Approved June 2021 General update (Migration to new template) March 2018 Updated Data plate Ermanni Orefici Vigliano April 2016 Updated applicable regulation (chapter 1.1.1) Ermanni Orefici Vigliano...

  • Page 3: Table Of Contents

    Pneumatic Cylinder ................16 3.1.2 Travel Stop Screw Screwed on the End Flange of Spring Container ................17 Calibration of Microswitches (Biffi Limit Switch Box Only) ......19 Calibration of Operating Time in Supply Operation ........22 Preparation for Start-up ................23 3.4.1 Pneumatic Connections ..............
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 6: Troubleshooting Failure or Breakdown Research ..............43 Section 7: Dismantling and Demolition Dismantling and Demolition..................44 Section 8: Layouts and Sectional Drawings Parts List for Maintenance and Replacing Procedure ........45 Section 9: Date Report for Maintenance Operations Date Report for Maintenance Operations...............50 Table of Contents...

  • Page 5: Section 1: General Warnings

    Biffi Italia will not be responsible for any mistakes contained in it or for any damage either accidental or due to the use of this manual. The information herein contained is reserved property of Biffi Italia and is subject to being modified without notice.

  • Page 6: Identification Plate

    MAN 689 Rev. 6 Identification Plate WARNING It is forbidden to modify the information and the marks without previous written authorization by Biffi Italia s.r.l. The plate fastened on the actuator contains the following information (Figure1). Figure 1 Data Plate...
  • Page 7 The actuator yoke has a hole with keyways suitable for the assembly of an insert bush or a stem extension. Their internal hole is machined (by Biffi or at Customer's care), according to the shape and dimensions of the valve stem.

  • Page 8: Section 2: Installation

    Section 2: Installation Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 2: Installation Checks to be Carried Out on Receiving the Actuator If the actuator arrives already assembled onto the valve, the settings of the mechanical stops and of the microswitches (if existing) has already been made by the person who assembled the actuator onto the valve.

  • Page 9: Assembling The Actuator Onto The Valve

    Types of Assembly For coupling to the valve, the housing is provided with a flange with threaded holes according to Biffi standard tables (SCN6200; SCN6200-1; SCN6201; SCN6201-1). The number, dimensions and diameter of the holes are made in accordance with ISO 5211, but for actuator models 0.3 to 6 the holes are drilled on the centerline in order to allow an...
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 3 Coupling Dimensions - Models 14, 18, 32, 35, 42 Drive sleeve Ø Ø +0.1 Ø ±0.2 Ø N. THREADED HOLES PCD, number and size according to ISO 5211 Flow line +0.2 Ø...
  • Page 11 Installation, Operation and Maintenance Manual Section 2: Installation MAN 689 Rev. 6 June 2021 Figure 4 Coupling Dimensions - Models 50, 60 Drive sleeve Ø Ø +0.1 Ø ±0.2 Ø N. THREADED HOLES Flange sizing according to ISO W D10 Flow line +0.2 +0.1...
  • Page 12 A-A, from position (1) Insert bush turned upside down The Biffi insert bush with 2 external keys at 45° allows to position the keyway for the valve every 90°. Consequently, actuator can be mounted in 4 positions at 90° on top of the valve.

  • Page 13: Valve Stem With Vertical Axis

    Installation, Operation and Maintenance Manual Section 2: Installation MAN 689 Rev. 6 June 2021 2.3.2 Valve Stem with Vertical Axis NOTICE The lifting and handling of the actuator must be done by qualified personnel and in accordance with the laws and regulations in force. Avoid the lifted actuator to be hung above the personnel.
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 7 Lifting points: 1-2 (obligatory) 3 (balancing) FRONT VIEW SIDE VIEW Lifting eyelet Pneumatic cylinder Lifting eyelet Lifting eyelet Spring cartridge Support brackets Lifting points to be used Lifting points to be used if if required for balancing required for balancing during...
  • Page 15 Installation, Operation and Maintenance Manual Section 2: Installation MAN 689 Rev. 6 June 2021 Lift actuators (pneumatic spring-return) by means of the proper lifting points represented and indicated on actuator by sticking labels. Also refer to Figure 7 for lifting points positions.
  • Page 16 Section 2: Installation Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 The actuator can be assembled onto the valve flange either by using the actuator-housing flange with threaded holes, or by the interposition of an adaptor flange or a spool piece. The actuator drive sleeve is generally connected to the valve stem by an insert bush or a stem extension.
  • Page 17 Installation, Operation and Maintenance Manual Section 2: Installation MAN 689 Rev. 6 June 2021 Table 6. Thread Size Recommended Tightening Torque (Nm) 1100 1400 1700 Installation...

  • Page 18: Valve Stem With Horizontal Axis

    Section 2: Installation Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 2.3.3 Valve Stem with Horizontal Axis The actuator can also be lifted to assemble directly onto the valve with stem with horizontal axis. To make a correct lifting procedure, proceed as follow: Connect properly the actuator lifting points 1 with chains, and connect by suitable slings the support brackets 2 and 3.
  • Page 19 Installation, Operation and Maintenance Manual Section 2: Installation MAN 689 Rev. 6 June 2021 Balance the weight and lift the actuator until to make possible rotation of actuator in its final mounting position, with cylinder on top, or spring container placed on top, as shown in Figure 11.

  • Page 20: Section 3: Operation And Use

    Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 3: Operation and Use Setting of the Angular Stroke It is important that the mechanical stops of the actuator (and not those of the valve) stop the angular stroke at both extreme valve position (fully open and fully closed), except when this is required by the valve operation (e.g.

  • Page 21: Travel Stop Screw Screwed On The End Flange Of Spring Container

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 689 Rev. 6 June 2021 Table 7. Hydraulic Cylinder Size Wrench C1 (mm) Wrench C2 (mm) Wrench C3 (mm) 3.1.2 Travel Stop Screw Screwed on the End Flange of Spring Container For the adjustment of the travel stop screw proceed as follows: (See Figure 13)
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Loosen the lock nut “d”. If the actuator angular stroke is stopped before reaching the end position, unscrew the stop screw “v” by turning it anticlockwise until the valve reaches the correct position.

  • Page 23: Calibration Of Microswitches (Biffi Limit Switch Box Only)

    Section 3: Operation and Use MAN 689 Rev. 6 June 2021 Calibration of Microswitches (Biffi Limit Switch Box Only) NOTICE Operate only the microswitch corresponding to the direction of operation being carried out, as clearly reported on the microswitch. WARNING If different microswitches assembly or limit switch box is supplied, please refer to the specific documentation.
  • Page 24 Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 15 Microswitches box Figure 16 Cam adjustment Operation and Use...
  • Page 25 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 689 Rev. 6 June 2021 If the index (Figure 20), does not signal the proper position of the valve but is turned by 90°: • Remove the roll pin placed on the position indicator (index). •...

  • Page 26: Calibration Of Operating Time In Supply Operation

    Calibration of Operating Time in Supply Operation The calibration of the operation time is made by Biffi Italia s.r.l. according to customer requirements and to technical data sheet included in technical documentation. If necessary, it’s possible to modify or to reset the operating time through the flow regulation valve placed between the control system and the pneumatic cylinder (Figure 18).

  • Page 27: Preparation For Start-Up

    Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 689 Rev. 6 June 2021 Preparation for Start-up 3.4.1 Pneumatic Connections Connect the actuator to the pneumatic feed line with fittings and pipes in accordance to the plant specifications. They must be sized correctly in order to guarantee the necessary airflow for the operation of the actuator, with pressure drops not exceeding the maximum allowable value.

  • Page 28: Start-Up

    Section 3: Operation and Use Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Start-up During the start-up of the actuator, proceed as follows: Check that the pressure and quality of the air supply (filtering degree, dehydration) are as prescript. Check that the feed voltage values of the electric components (solenoid valve coils, microswitches, pressure switches, etc.) are as prescript.

  • Page 29: Section 4: Operational Tests And Inspections

    Installation, Operation and Maintenance Manual Section 4: Operational Tests and Inspections MAN 689 Rev. 6 June 2021 Section 4: Operational Tests and Inspections NOTICE To ensure the guaranteed SIL grade, according to IEC 61508, the functionality of actuator must be checked with regular intervals of time, as described in the Safety Manual. Operational Tests and Inspections...

  • Page 30: Section 5: Maintenance

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 5: Maintenance NOTICE Before carrying out any maintenance operation, it is necessary to close the pneumatic feed line and exhaust the pressure from the actuator cylinder and from the control unit, to ensure safety of maintenance staff.

  • Page 31: Special Maintenance

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 Special Maintenance If there are leaks in the hydraulic cylinder, pneumatic cylinder or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembly and seals must be replaced with reference to the follow general sectional drawing and adopting the following procedures.

  • Page 32: Replacement Of Cylinder Seals

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 5.2.1 Replacement of Cylinder Seals Refer to the following sectional drawing. Measure the protrusion of the stop screw (26) with reference to the end flange (22) surface, so as to be able to easily restore the setting of the actuator mechanical stop, once the maintenance procedures have been completed.
  • Page 33 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 5.2.1.2 Reassemble Assemble the new gasket (36) after cleaning the surfaces of housing (8) and head flange (17) which are in contact. Assemble the head flange (17), replace the washers (37) if damaged, tighten the screws (15) to the recommended torque.
  • Page 34 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 21 ALGAS-MHP Single Acting Pneumatic Actuator with Hydraulic Manual Override Table 10. Item Description Cover Screw Guide block pin Vent valve Sliding block Screw Screw...
  • Page 35 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 Item Description Cylinder tube Piston rod Piston End flange Lifting eyelet Spring washer Gasket Screw Stopper bush Container rod Adaptor bush Washer O-ring Yoke bushing Retainer ring Gasket Washer Piston rod bushing...

  • Page 36: Replacement Of Hydraulic Cylinder Seals

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 5.2.2 Replacement of Hydraulic Cylinder Seals If there are leaks in the hydraulic cylinder or a malfunction in the mechanical components, or in case of scheduled preventive maintenance, the actuator must be disassembled and seals must be replaced with reference to the sectional drawing and adopting the following procedures: Remove the nuts (item 16) and the washers (item 15) from the tie rods (item 10)
  • Page 37 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 If the O-ring (17) has to be replaced, measure the protrusion of the stop screw (11) with reference to the end flange (13) surface, so as to be able to easily restore the setting of the actuator mechanical stop in the correct previous valve position, once the maintenance procedures have been completed.
  • Page 38 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 22 Cylinder Table 11. Item Description Material Piston rod bushing Steel + BZ + Teflon Head flange Carbon steel O-ring * NBR rubber Piston rod seal ring * Teflon + graphite O-ring * NBR rubber...

  • Page 39: Mhp Hydraulic Manual Override Maintenance And Troubleshooting

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 MHP Hydraulic Manual Override Maintenance and Troubleshooting 5.3.1 Operation (See the attached operating diagram, Figure 23). The “MHP” hydraulic manual override is utilized, in connection with the actuator hydraulic cylinder, for the manual operation of the actuators.

  • Page 40: Check Of Oil Level Into The Oil Tank

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 5.3.4 Check of Oil Level Into the Oil Tank (See the attached sectional drawings). During the actuator operation the oil tank has to be closed (not in connection with the atmosphere).

  • Page 41: Maintenance For Mhp

    Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 Low temperature conditions (until -60 °C) Manufactured Name SYNTESIS SYNTRASS-CS 500 Viscosity at -60 °C 580 cST Viscosity at -30 °C 39 cST Viscosity at 20 °C 5,8 cST Viscosity at 50 °C 2,1 cST...
  • Page 42 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 23 MAN686-A 1 - Scotch yoke mechanism 2 - Spring Cartridge 3 - Hydraulic Cylinder R - Relief valve P - Handpump D - Hand operated directional control valve Ot - Oil tank 351 - Stop valve 395 - Relief valve...
  • Page 43 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 Figure 24 Hydraulic Manual Handpump Maintenance...
  • Page 44 Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Table 13. Item Description Material Dipstick Cap nut Carbon steel Washer Carbon steel + rubber Hydraulic tank Carbon steel Handpump See attached table O-ring * Fluorosilicon rubber Ball Stainless steel Spring...
  • Page 45 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 689 Rev. 6 June 2021 Item Description Material Plug Carbon steel O-ring * Fluorosilicon rubber Spacer Stainless steel Screw Stainless steel Spring pin Carbon steel Screw Carbon steel Operation instruction plate Stainless steel Screw Carbon steel...

  • Page 46: Lubrication Of Mechanism

    Section 5: Maintenance Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Lubrication of Mechanism For normal duty, the scotch yoke mechanism of the actuator is lubricated "for life". In case of high load and high frequency of operation it may be necessary to periodically restore lubrication: it is advisable to apply a generous coating of grease on the contact surfaces of the yoke and bushings, on the yoke link grooves, on the sliding blocks, on the guide bar.

  • Page 47: Section 6: Troubleshooting

    Restore correct position the manual hydraulic group Actuator does not work Failure of the spring Call Biffi Italia s.r.l. Customer Service Failure of the control group Call Biffi Italia s.r.l. Customer Service Unexpected intervention of torque Call Biffi Italia s.r.l. Customer Service...

  • Page 48: Section 7: Dismantling And Demolition

    Section 7: Dismantling and Demolition Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 7: Dismantling and Demolition Before starting the disassembly a large area should be created around the actuator so to allow any kind of movement without problems of further risks created by worksite. WARNING Before disassembling the actuator it is necessary to close the pneumatic feed line and discharge pressure from the cylinder of the actuator, from the control unit and from the...

  • Page 49: Section 8: Layouts And Sectional Drawings

    * Cycles perfromed by actuator in a 25 years expected lifetime - The minimum performed cycles are guaranteed by Biffi based on service conditions listed: - All the valve required torques have to be lower than actuator max operating torque (MOT) - The ration between valve required running torque and actuator max operating torque (MOT) has to be >1,5.
  • Page 50 * Cycles perfromed by actuator in a 25 years expected lifetime - The minimum performed cycles are guaranteed by Biffi based on service conditions listed: - All the valve required torques have to be lower than actuator max operating torque (MOT) - The ration between valve required running torque and actuator max operating torque (MOT) has to be >1,5.
  • Page 51 Installation, Operation and Maintenance Manual Section 8: Layouts and Sectional Drawings MAN 689 Rev. 6 June 2021 Figure 27 Pneumatic cylinder Table 18. Parts list Item Description Material Piston rod bushing Steel + Bz + Teflon O-ring * NBR O-ring * NBR Head flange Carbon steel...
  • Page 52 Section 8: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Figure 28 Spring cartridge Table 19. Parts list Item Description Material Carbon steel Washer Carbon steel Sealing washer * PVC Stop setting screw Carbon steel Spring container Carbon steel...
  • Page 53 Installation, Operation and Maintenance Manual Section 8: Layouts and Sectional Drawings MAN 689 Rev. 6 June 2021 Figure 29 Assembly kit Table 20. Parts list Item Description Material Screw Alloy steel Gasket * Fiber Side plate Carbon steel Gasket * Fiber Washer Carbon steel Adaptor bush...

  • Page 54: Section 9: Date Report For Maintenance Operations

    Section 9: Date Report for Maintenance Operations Installation, Operation and Maintenance Manual June 2021 MAN 689 Rev. 6 Section 9: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 55 Installation, Operation and Maintenance Manual Notes MAN 689 Rev. 6 June 2021 This page is intentionally left blank...
  • Page 56 VCIOM-03199-EN ©2021 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for information purposes only, 29017 Fiorenzuola d’Arda (PC) and while every effort has been made to ensure their accuracy, they are not...

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