BIFFI ALGA - EAC User manual

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

May 2023

Bif ALGA - EAC

Double-Acting Pneumatic Actuator

Bif Italia s.r.l. - Strada Bif 165, 29017 Fiorenzuola d’Arda (PC) – Italy PH: +39 0523 944 411 – bif_italia@bif.it

May 2023

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

Notes

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Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3 May 2023

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 Identication 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 Microswitches (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

May 2023

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

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 Troubleshooting.......... 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

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3 May 2023

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

May 2023

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

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 specications, 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 specied 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 modied 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 modication

or tampering whatsoever be performed on the actuator.

1.2 Identication 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, buttery valves or dampers, in both ON-OFF and

Modulating heavy duty service.

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3 May 2023

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. Identication of Actuator Parts

1.4 Data Sheet

Supply uid Air, nitrogen or sweet gas, special version available for sour gas

Operating temperature Standard: from -30 to +100 °C

Optional: from -60 to +200 °C

Supply pressure Please refer to technical document: “actuator data sheet”

Output torque Up to 750000 Nm (higher value with special version)

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)

May 2023

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

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 identication plate correspond with those of order conrmation

(Section 1.2).

• Check that the actuator is equipped with the ttings as provided for by

order conrmation.

• Check that the actuator was not damaged during transportation: if necessary

renovate the painting according to the specication reported on the order

conrmation.

• 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

microswitches (if any) (Section 3.5).

2.2 Actuator Handling

NOTICE

The lifting and handling should be made by qualied 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

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3 May 2023

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 = Do not lay the actuator on tie-rods of cylinder/s and do not lay the actuator on

accessories (manual handpump, manual jackscrew, pneumatic control group etc.)

1, 2 = Lifting points (obligatory)

3 = Balancing point

May 2023

Installation, Operation and Maintenance Manual

MAN 564_EAC Rev. 3

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

PERSONAL 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

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