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BIFFI ALGAS Installation, Operation And Maintenance Manual

Spring-return pneumatic actuator
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Installation, Operation and Maintenance Manual
MAN 604C Rev. 3
July 2024
Biffi ALGAS
Spring-Return Pneumatic Actuator
Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manual 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' A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it

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Summary of Contents for BIFFI ALGAS

  • Page 1 Copyright © Biffi. The information in this document is subject to change without notice. Updated installation, operation and maintenance manual 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’ A rda (PC) – Italy PH: +39 0523 944 411 – biffi_italia@biffi.it...
  • Page 2 Notes Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 This page is intentionally left blank.
  • Page 3 Travel Stop Screw Screwed at the End Flange of Pneumatic Cylinder ................16 3.1.2 Stop Screw Screwed at the End Flange of Spring Container ..17 Microswitches Calibration (Biffi Limit Switch Box Only) ....... 18 Calibration of Operating Time ................21 Preparation for Start-up ..................22 3.4.1 Pneumatic Connections .................
  • Page 4 Table of Contents Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Section 7: Layouts and Sectional Drawings Parts List for Maintenance and Replacement Procedure ......34 Section 8: Spare Parts Spare Parts ........................38 Section 9: Date Report for Maintenance Operations Date Report for Maintenance Operations ..............
  • Page 5 Nevertheless, Biffi Italia s.r.l. does not provide any guarantees for this manual. Biffi Italia s.r.l. 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 s.r.l.
  • Page 6 Charging Hazard See Instructions Description of the Actuator ALGAS low pressure pneumatic spring-return, are suitable for the operation of quarter-turn valves (ball valves, butterfly valves, plug valves) in both on/off and modulating heavy-duty service. The actuator is made up of a weatherproof scotch yoke mechanism transforming...
  • 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 Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Section 2: Installation Checks to Be Carried Out Upon Receiving the Actuator If the actuator arrives already assembled onto the valve, the settings of the mechanical stops and of the microswitches (if existing) have already been made by the person who assembled the actuator onto the valve.
  • Page 9 The yoke is bored with keyways for coupling to the valve stem, the dimensions of which are according to Biffi standard tables SCN6200 and SCN6201 (see Tables 2 to 5 for more details). Installation...
  • Page 10 Section 2: Installation Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Figure 2. Coupling Dimensions - Models 0.3 to 6 DRIVE SLEEVE Ø d +0.1 Ø d Ø d ±0.2 Ø d N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 (BUT THE HOLES ARE ON CENTERLINE INSTEAD OF...
  • Page 11 Installation, Operation and Maintenance Manual Section 2: Installation MAN 604C Rev. 3 July 2024 Figure 3. Coupling Dimensions - Models 14, 18, 32, 35 and 42 DRIVE SLEEVE Ø d Ø d +0.1 Ø d ±0.2 Ø d N. THREADED HOLES PCD, HOLES, NUMBER AND SIZE ACCORDING TO ISO 5211 FLOW LINE...
  • Page 12 Section 2: Installation Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Figure 4. Coupling Dimensions - Models 50 and 60 DRIVE SLEEVE Ø d Ø d +0.1 Ø d ±0.2 Ø d N. THREADED HOLES FLANGE SIZING ACCORDING TO ISO 5211 FLOW LINE Ø...
  • Page 13 MAN 604C Rev. 3 July 2024 If required, for the standard models size 0.3 to 6, Biffi can supply an insert bush with unmachined bore in accordance with Biffi standard table SCN6202. On request, the insert bush bore can be machined by Biffi to couple the valve stem, provided its dimensions match the maximum stem acceptance of the bush according to Biffi table TN1005 (ask the factory) and refer to Figure 5.
  • Page 14 Section 2: Installation Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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 hanging the lifted actuator above any personnel.
  • Page 15 LIFTING EYELET SPRING CARTRIDGE PNEUMATIC CYLINDER Lift  ALGAS 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. • For lifting unbalanced loads, use ropes of different lengths or chains with adjustable length.
  • Page 16 WARNING Any lifting method different from what described above is strictly forbidden. Biffi rejects any responsibility for damages to goods or injuries to personnel coming from incorrect lifting operations. 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.
  • Page 17 Installation, Operation and Maintenance Manual Section 2: Installation MAN 604C Rev. 3 July 2024 Connect a sling to the support points of the actuator and lift it: make sure the sling is suitable for the actuator weight. When possible, it is easier to assemble the actuator to the valve if the valve stem is in the vertical position.
  • Page 18 Section 2: Installation Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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: Properly connect 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 604C Rev. 3 July 2024 Balance the weight and lift the actuator until its possible to rotate the actuator to its final mounting position with cylinder on top or spring container placed on top, as shown in Figure 11. Figure 11.
  • Page 20 Section 3: Operation and Use Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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., metal seated butterfly valves).
  • Page 21 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604C Rev. 3 July 2024 3.1.2 Stop Screw Screwed at the End Flange of Spring Container For the adjustment of the travel stop screw proceed as follows: See Figure 13. Figure 13.
  • Page 22 Section 3: Operation and Use Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Microswitches Calibration (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 23 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604C Rev. 3 July 2024 Figure 14. Microswitches Box Figure 15. Cam Adjustment Box Operation and Use...
  • Page 24 Section 3: Operation and Use Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 If the index (Figure 16), 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 25 July 2024 Calibration of Operating Time 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 is possible to modify or to reset the operating time through the flow regulation valve placed between the control system and the pneumatic cylinder (Figure 17).
  • Page 26 Section 3: Operation and Use Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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 27 Installation, Operation and Maintenance Manual Section 3: Operation and Use MAN 604C Rev. 3 July 2024 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 28 Section 4: Operational Tests and Inspections Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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.
  • Page 29 Installation, commissioning and maintenance and repair works should be carried out by qualified staff. Routine Maintenance ALGAS  actuators have been designed to work for long periods in the most severe conditions with no need for maintenance. NOTICE Periodicity and regularity of inspections is particularly influenced by specific environmental and working conditions.
  • Page 30 Section 5: Maintenance Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Extraordinary 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 31 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 604C Rev. 3 July 2024 5.2.1 Replacement of Cylinder Seals Refer to Figure 19. 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 32 Section 5: Maintenance Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 5.2.1.2 Cylinder Reassembling Carefully clean the inside of the tube (19) and check that the entire surface, particularly that of the bevels, is not damaged. Lubricate the inside surface of the tube and the bevels at the ends.
  • Page 33 Installation, Operation and Maintenance Manual Section 5: Maintenance MAN 604C Rev. 3 July 2024 Figure 19. ALGAS Spring-Return Pneumatic Actuator 15 16 41 42 Table 7. Parts List (1) Item Description Stop setting screw Spring container Spring Shoulder washer Rod bushing...
  • Page 34 Section 5: Maintenance Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Table 8. Parts List (2) Item Description Cylinder tube Piston rod Piston End flange Lifting eyelet Spring washer Stop setting screw cover Stop setting screw Guide rod Spring thrust flange Rod bushing Container rod...
  • Page 35 If the service is not special (i.e., oxygen, hydrogen or other mentioned during the offer stage). Use an equivalent or better product in compliance with the grease proposed in the actual scope of supply by Biffi Fiorenzuola. Your grease supplier can verify and propose an alternative product at your responsibility. Maintenance...
  • Page 36 Section 5: Maintenance Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 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.
  • Page 37 Restore correct position 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 38 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Section 7: Layouts and Sectional Drawings Parts List for Maintenance and Replacement Procedure Figure 20. Scotch Yoke Mechanism Table 10. Parts List Item Quantity Description Material...
  • Page 39 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings MAN 604C Rev. 3 July 2024 Figure 21. Pneumatic Cylinder with Setting Screw Protection Table 11. Parts List Item Quantity Description Material Piston rod bushing Steel + Bronze + PTFE O-ring * Viton ®...
  • Page 40 Section 7: Layouts and Sectional Drawings Installation, Operation and Maintenance Manual July 2024 MAN 604C Rev. 3 Figure 22. Spring Cartridge with Setting Screw Protection Table 12. Parts List Item Quantity Description Material Stop setting screw cover Carbon steel Plug with gasket Stainless steel + Viton O-ring * NBR rubber...
  • Page 41 Installation, Operation and Maintenance Manual Section 7: Layouts and Sectional Drawings MAN 604C Rev. 3 July 2024 Figure 23. Assembly Kit Table 13. Parts List Item Quantity Description Material Screw Alloy steel Gasket * Fiber Side plate Carbon steel Gasket * Fiber Washer Carbon steel...
  • Page 42 MAN 604C Rev. 3 Section 8: Spare Parts For spare parts orders to the relevant Biffi  o ffice please make reference to Biffi    order confirmation concerning all the supply, and serial number of the actuator (Section 1.2) for any specific spare part for a specific actuator model.
  • Page 43 Installation, Operation and Maintenance Manual Section 9: Maintenance Operations MAN 604C Rev. 3 July 2024 Section 9: Date Report for Maintenance Operations Last maintenance operation date: (in factory, on delivery): ……… exec. by : ………… ……… exec. by : ………… ………...
  • Page 44 VCIOM-16474-EN © 2016, 2024 Biffi. All rights reserved. Biffi Italia s.r.l. Strada Biffi 165 The contents of this publication are presented for informational purposes 29017 Fiorenzuola d’Arda (PC) only, and while every effort has been made to ensure their accuracy,...