BIFFI ALGA-EAC Series User manual
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
June 2020
Bif ALGA - EAC
Double-Acting Pneumatic Actuator
Copyright © Bif. The information in this document is subject to change without notice. Updated data sheets can be obtained from our website www.bif.it or from your nearest Bif Center:
Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d'Arda (PC) – Italy PH: +39 0523 944 411 – bif_italia@bif.it
June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Revision Details
Revision Details
Rev. Date Description Prepared Checked Approved
2 June 2020 General update (migration to new template)
1 March 2018 Updated data-plate Ermanni Oreci Vigliano
0January 2017 Document release Ermanni Oreci Vigliano
Revision Details
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Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Table of Contents
Table of Contents
Table of Contents
Section 1: General warnings
1.1 Generalities.................................................................................................... 1
1.1.1 Applicable Regulation ......................................................................... 1
1.1.2 Terms and Conditions.......................................................................... 2
1.2 Identication Plate ......................................................................................... 2
1.3 Introducing the Actuator................................................................................ 2
1.4 Data Sheet ..................................................................................................... 3
Section 2: Installation
2.1 Checks Upon Actuator Receipt ....................................................................... 4
2.2 Actuator Handling.......................................................................................... 4
2.3 Storage .......................................................................................................... 7
2.4 Actuator Assembly on the Valve..................................................................... 7
2.4.1 Types of Assembly............................................................................... 7
2.4.2 Assembly Procedure.......................................................................... 12
2.5 Pneumatic Connections ............................................................................... 13
2.6 Electrical Connections (If Any)...................................................................... 14
2.7 Commissioning............................................................................................ 15
Section 3: Operation and Use
3.1 Operation Description.................................................................................. 16
3.2 Residual Risks............................................................................................... 22
3.3 Calibration of the Angular Stroke ................................................................. 22
3.4 Calibration of Micro-switches (If Foreseen)................................................... 28
3.5 Calibration of the Operation Time (Optional - If Foreseen)............................ 29
Section 4: Operational Tests and Inspections
Operational Tests and Inspections................................................................ 31
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June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Table of Contents
Table of Contents
Section 5: Maintenance
5.1 Periodic Maintenance................................................................................... 32
5.1.1 Check and Restore Oil Level in the Hydraulic Manual Override ........... 33
5.1.2 Gas Supply Dehydrating Filter Maintenance (If Foreseen)................... 35
5.2 Extraordinary Maintenance .......................................................................... 36
5.2.1 Replacement of Cylinder Seals ........................................................... 36
5.3 MHP Hydraulic Manual Override Maintenance and Trouble Shooting............ 45
5.3.1 Operation.......................................................................................... 45
5.3.2 Manual Operation ............................................................................. 45
5.3.3 Remote Operation............................................................................. 45
5.3.4 Setting .............................................................................................. 46
5.4 Lubrication of Mechanism ............................................................................ 48
5.5 Dismantling and Demolition ........................................................................ 49
Section 6: Troubleshooting
6.1 Failure or Breakdown Research ..................................................................... 50
Section 7: Layouts
7.1 Spare Parts Order......................................................................................... 51
7.2 Parts List for Maintenance and Replacing Procedure..................................... 52
Section 8: Date Report for Maintenance Operations
Date Report for Maintenance Operations ..................................................... 60
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Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
General Warnings
Section 1: General Warnings
NOTICE
The manual is an integral part of the machine, it should be carefully read before carrying
out any operation and it should be kept for future references.
1.1 Generalities
Bif Italia s.r.l. actuators are conceived, manufactured and controlled according to the
Quality Control System in compliance with EN-ISO 9001 international regulation.
1.1.1 Applicable Regulation
EN ISO 12100:2010: Safety of machinery – General principles for design –
Risk assessment and risk reduction
2006/42/EC: Machine directive
2014/68/EU: Directive for pressure PED equipment
2014/35/EU: Directive for low voltage equipment
2014/30/EU: Directive for the electromagnetic compatibility
2014/34/EU: Directive and safety instructions for use in hazardous area
TR TS 004/2011 Customs Union Technical Regulation
(For safety of low voltage equipment)
TR TS 010/2011 Customs Union Technical Regulation
(For safety of equipment and machines)
TR TS 012/2011 Customs Union Technical Regulation
(For safety of equipment operated in explosive atmosphere)
TR TS 020/2011 Customs Union Technical Regulation
(Electromagnetic Compatibility of Technical Products)
TR TS 032/2013 Customs Union Technical Regulation
(For safety of Excess Pressure Equipment)
Section 1: General Warnings
NOTICE
Bif Italia s.r.l. pays the highest attention to collecting and verifying the documentation
contained in this user manual. However Bif Italia s.r.l. is not liable for any mistakes
contained in this manual, for damage or accidents due to the use of the latter. The
information contained is of exclusive reserved ownership of Bif Italia s.r.l. and may
be modied without prior notice. All rights reserved.
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June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
General Warnings
1.1.2 Terms and Conditions
Bif Italia s.r.l. guarantees that all the items produced are free of defects in workmanship
and manufacturing materials and meet relevant current specications, provided they
are installed, used and serviced according to the instructions contained in the present
manual. The warranty can last either one year from the date of installation by the initial
user of the product, or eighteen months from the date of shipment to the initial user,
depending on which event occurs rst. All detailed warranty conditions are specied in the
documentation forwarded together with the product. This warranty does not cover special
products or components not warranted by subcontractors, or materials that were used or
installed improperly or were modied or repaired by unauthorized staff. In the event that
a fault condition be caused by improper installation, maintenance or use, or by irregular
working conditions, the repairs will be charged according to applicable fees.
The warranty and Bif Italia s.r.l. liability shall lapse in the event that any modication
or tampering whatsoever be performed on the actuator.
1.2 Identication Plate
It is forbidden to modify the information and the marks without previous written
authorization by Bif Italia s.r.l.
The plate fastened on the actuator contains the following information (Figure 1).
Figure 1 Data Plate
Section 1: General Warnings
1.3 Introducing the Actuator
The ALGA actuators was engineered and is manufactured to provide maximum torque
output with minimum supply pressure. Alga actuators are suitable for the operation of any
quarter turn operation such of ball, plug, buttery valves or dampers, in both ON-OFF and
Modulating heavy duty service.
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Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
General Warnings
Section 1: General Warnings
The actuator (see Figure 2) is made up of a weatherproof scotch yoke mechanism
transforming the linear movement of the pneumatic cylinder (on closing or opening) into
the rotary movement, which is necessary for operation. The angular stroke of the yoke is
adjustable between 82° and 98° by means of the external mechanical stops screwed into
the left wall of the mechanism housing and into the end ange of the pneumatic cylinder.
The cover of the scotch yoke mechanism is arranged for the assembly of the required
accessories (positioner, signalling limit switches, position transducer, etc.) by means of
proper matching units. The above mentioned accessories are operated by the actuator
drive sleeve. The housing of the scotch yoke mechanism has a ange with threaded holes
to x the actuator to the valve either directly or, if required, with the interposition of an
adaptor ange or a mounting bracket. The actuator yoke has a hole with keyways suitable
for the assembly of an insert bush the internal hole of which is machined (by Bif or at
Customer's care), according to the shape and dimensions of the valve stem. Bif can
supply different types of control system following Customer's requirements.
The expected lifetime of actuator is approximately 25 years.
Figure 2 Identication of Actuator Parts
Manual handpump
MHP (optional)
Control system
(optional)
Valve
coupling
Pneumatic
cylinder
Valve position
indicator
Scotch yoke
mechanism
Hydraulic cylinder for ALGA-MHP
models or second pneumatic
cylinder for ALGA*2 double
cylinder models (optional)
1.4 Data Sheet
Supply uid Air, nitrogen or sweet gas, special version available for sour gas
Operating temperature Standard: from –30 °C to +100 °C
Optional: from –60 °C to +200 °C
Supply pressure Please refer to technical document: “actuator data-sheet”
Output torque Up to 750000 Nm (higher value with special version)
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Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
2.1 Checks Upon Actuator Receipt
• Check that the model, the serial number of the actuator and the technical data
reported on the identication plate correspond with those of order conrmation
(Section 1.2).
• Check that the actuator is equipped with the ttings as provided for by order
conrmation.
• Check that the actuator was not damaged during transportation: if necessary
renovate the painting according to the specication reported on the order
conrmation.
• If the actuator is received already assembled with the valve, its settings have
already been made at the factory.
• If the actuator is delivered separately from the valve, it is necessary to check, and,
if required, to adjust, the settings of the mechanical stops (Section 3.4) and of
micro-switches (if any) (Section 3.5).
2.2 Actuator Handling
NOTICE
The lifting and handling should be made by qualied staff and in compliance with the laws
and provisions in force.
!WARNING
The fastening points are appropriate for the lifting of the actuator alone and not for the
valve + actuator assembly. Avoid that during the handling, the actuator passes above the
staff. The actuator should be handled with appropriate lifting means. The weight of the
actuator is reported on the delivery bill.
For lifting and moving the actuator, use only hooks tted with safety latch, like the one,
for example, shown in Figure 3.
Figure 3 Example of Hook with Safety Latch
Section 2: Installation
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Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2 June 2020
Installation
Section 2: Installation
Figure 4 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators
Figure 5 Lifting points for ALGA / ALGA-MHP / ALGA-MSJ actuators
1 = Point of support
2 = Supports for lateral positioning
3 = Don’t lay the actuator on tie-rods of cylinder /s and don’t lay the actuator on
accessories (manual handpump, manual jackscrew, pneumatic control group etc.)
1, 2 = Lifting points (obligatory)
3 = Balancing point
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June 2020
Installation, Operation and Maintenance Manual
MAN 564_EAC Rev. 2
Installation
Section 2: Installation
• For lifting unbalanced loads, use ropes of different lengths or chains with
adjustable length.
• Check each time the conditions of all lifting equipment used and discard it if
not in perfect working order.
• Do not knot or twist the ropes so as not to reduce the lifting capacity or
produce torsional effects on the load being lifted.
• Use the utmost caution and remain at a safe distance from lifted actuator
unless absolutely necessary; do not stand or pass under suspended loads.
• Pay attention in putting under tension the ropes to prevent the load shifting
sideways in an uncontrolled manner.
• Use slings of such length that the angles of the leg from vertical are as narrow
as possible (αMAX < 20°).
• During handling, do not transport the suspended actuator above staff
members in charge of the operation.
!WARNING
Do not use the lifting eyelets on actuator to lift valve + actuator assembly.
Figure 6
!WARNING
Any lifting method different from what described above is strictly forbidden.
Bif reject any responsibility for damages to goods or injuries to persons coming from
wrong lifting operations.
BIFFI IS NOT LIABLE FOR ANY
PERSONEL INJURY DUE TO
INCORRECT USE
DO NOT DISASSEMBLE TOP OR
BOTTOM COVER.
SPRING LOADED.
POTENTIAL ELECTROSTATIC CHARGE HAZARD
REFER TO IOM
LIFTING LUGS TO BE USED FOR THE
ACTUATOR ONLY. DO NOT LIFT
VALVE AND ACTUATOR TOGETHER
This manual suits for next models
2
Table of contents
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