BIFFI ALGAS-MHP, Installation, Operation And Maintenance Manual

Page 1: ...ed 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 Biffi ALGAS MHP Spring Return Pneumatic Actuator with Hydraulic Handpump Installation Operation and Maintenance Manual MAN 689 Rev 6 June 2021 ...

Page 2: ...n chapter 1 1 1 Ermanni Orefici Vigliano 3 July 2014 Updated doc index Ermanni Cristalli Orefici 2 June 2012 Updated document Ermanni Stoto Vigliano 1 January 2012 Added vertical assembly description Ermanni Stoto Vigliano 0 September 2011 Document release Ermanni Stoto Vigliano Revision Details Installation Operation and Maintenance Manual MAN 689 Rev 6 June 2021 Revision Details Revision Details...

Page 3: ... the End Flange of Pneumatic Cylinder 16 3 1 2 Travel Stop Screw Screwed on the End Flange of Spring Container 17 3 2 Calibration of Microswitches Biffi Limit Switch Box Only 19 3 3 Calibration of Operating Time in Supply Operation 22 3 4 Preparation for Start up 23 3 4 1 Pneumatic Connections 23 3 4 2 Electrical Connections 23 3 5 Start up 24 Section 4 Operational Tests and Inspections Operationa...

Page 4: ...ion 6 Troubleshooting 6 1 Failure or Breakdown Research 43 Section 7 Dismantling and Demolition Dismantling and Demolition 44 Section 8 Layouts and Sectional Drawings 8 1 Parts List for Maintenance and Replacing Procedure 45 Section 9 Date Report for Maintenance Operations Date Report for Maintenance Operations 50 ...

Page 5: ...ained 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 first All detailed warranty conditions are specified in the documentation forwarded together with the product This warranty does not cover special products or components no...

Page 6: ...n pack incorporates up to four springs fully encapsulated in a factory welded cartridge this ensures safety to personnel and simplifies assembly The spring action can be easily changed in the field from to close in to open or from to open in to close modular design The angular stroke of the yoke is adjustable between 82 and 98 by means of the external mechanical stops screwed into the end flange o...

Page 7: ...me of actuator is approximately 25 years Table 1 Single Acting Low Pressure Pneumatic Actuators Coding System 3 Section 1 General Warnings The housing of the scotch yoke mechanism has a flange with threaded holes to fix the actuator to the valve either directly or if required with the interposition of an adaptor flange or a mounting bracket The actuator yoke has a hole with keyways suitable for th...

Page 8: ...nteed by an individual inspection certificate in order to maintain these characteristics until the actuator is installed on the plant it is necessary to observe a few rules and take appropriate measures during the storage period 1 Make sure that plugs are fitted in the air connections and in the cable entries The plastic plugs which close the inlets do not have a weatherproof function but are only...

Page 9: ...actuator models 0 3 to 6 the holes are drilled on the centerline in order to allow an easier assembly of an intermediate flange when required This intermediate flange or spool piece can be supplied when the valve flange cannot directly match the actuator flange in its standard configuration For the biggest actuator models the actuator flange can be machined in accordance with the valve flange dime...

Page 10: ...D number and size according to ISO 5211 Drive sleeve 0 Ø d2 0 1 Ø d3 0 2 Ø d1 max N 12 holes flange N 16 holes flange H max 0 h 1 0 5 D10 W Ø d5 0 2 0 1 Table 3 SCN 6201 Dimensions in millimeters Actuator model Ø d1 Ø d3 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K 14 580 250 483 M36 12 10 29 340 175 45 195 8 18 680 290 603 M36 16 12 32 350 200 45 220 8 32 780 290 603 M36 16 12 32 400 220 50 242 8 35 780 315 ...

Page 11: ...s in millimeters Actuator model Ø d1 Ø d2 Ø d3 Ø d4 N h1 h2 H max Ø d5 W K 7 Section 2 Installation Figure 4 Coupling Dimensions Models 50 60 Drive sleeve h 2 W D10 Ø d5 K 0 4 0 H max 0 h 1 0 5 Ø d4 Ø d1 max Ø d3 0 2 0 Ø d2 0 1 N THREADED HOLES Flange sizing according to ISO Flow line Top view of the scotch yoke mechanism actuator shown in closed position 0 2 0 1 Table 4 SCN 6201 1 ...

Page 12: ... to the dimensions of valve stem 8 Section 2 Installation 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 enclose...

Page 13: ...nel and in accordance with the laws and regulations in force Avoid the lifted actuator to be hung above the personnel WARNING The actuator must be lifted by means of a suitable lifting apparatus The weight of the actuators is indicated in the technical documentation attached to the equipment itself For lifting and moving the actuator use only hooks fitted with safety latch like the one for example...

Page 14: ... if required for balancing during lifting procedure or for lifting in vertical during lifting procedure Lifting points to be used if required for balancing during lifting procedure Support brackets Pneumatic cylinder Lifting eyelet Lifting eyelet Spring cartridge FRONT VIEW SIDE VIEW Lifting eyelet Lifting eyelet Lifting point applicable for models 0 3 0 9 1 5 Lifting eyelet Lifting point applicab...

Page 15: ... 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 9 WARNING Any lifting method different fr...

Page 16: ...ve stem and fasten it by tightening the proper stop dowels 6 Bring the actuator to the position caused by the spring operation 7 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 In this case the actuator must be lift...

Page 17: ...Maintenance Manual MAN 689 Rev 6 June 2021 Installation Thread Size Recommended Tightening Torque Nm M8 20 M10 40 M12 70 M14 110 M16 160 M20 320 M22 420 M24 550 M27 800 M30 1100 M33 1400 M36 1700 Table 6 13 Section 2 Installation ...

Page 18: ...he valve with stem with horizontal axis To make a correct lifting procedure proceed as follow 1 Connect properly the actuator lifting points 1 with chains and connect by suitable slings the support brackets 2 and 3 Figure 10 Lifting eyelets 1 Support brackets 2 Lifting eyelets 1 Support brackets 3 Hydraulic cylinder for manual override Don t use for lift 14 Section 2 Installation ...

Page 19: ...sembled on the valve stem enters the actuator drive sleeve without forcing the coupling When the insert bush has entered the actuator drive sleeve check the holes of the valve flange If they do not meet with the holes of the actuator flange or the stud bolts screwed into them the actuator drive sleeve must be rotated feed the actuator cylinder with air at proper pressure indicated on data sheet fo...

Page 20: ...d by adjusting the travel stop screw on the right side of the actuator 3 1 1 Travel Stop Screw Screwed on the End Flange of Pneumatic Cylinder For the adjustment of the travel stop screws proceed as follows 1 Remove the protection plug t with proper wrench c1 2 Loosen the stopper protection with a proper wrench c3 3 If the actuator angular stroke is stopped before reaching the end position fully o...

Page 21: ... 10 36 135 22 10 36 175 22 14 46 200 27 14 46 235 27 17 65 280 27 17 65 300 36 17 110 Table 7 Figure 13 Spring cartridge model from 006 to 150 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 Figure 14 Spring cartridge model from 200 to 15600 17 Section 3 Operation and Use ...

Page 22: ... position 4 If the actuator angular stroke is stopped beyond the end position screw the stop screw by turning it clockwise until the valve reaches the correct position 5 Tighten the lock nut after having correctly placed the threaded seal washer s and w To operate the adjustments refer to following tables Spring Container Size Wrench C1 mm Wrench C2 mm 006 46 41 008 46 41 009 46 41 0100 46 41 0150...

Page 23: ...follow these steps Unscrew the fastening screws of the cover Figure 15 Remove the cover paying attention not to deteriorate the gasket and the cylindrical and flat coupling surfaces Operate the actuator in opening or closing with local pneumatic or hydraulic operation Section 3 3 Unscrew the screw of the operating cam relative to the microswitch to calibrate and adjust it according to the settings...

Page 24: ...June 2021 Installation Operation and Maintenance Manual MAN 689 Rev 6 Operation and Use Figure 15 Microswitches box Figure 16 Cam adjustment 20 Section 3 Operation and Use ...

Page 25: ...y 90 Remove the roll pin placed on the position indicator index Turn the indicator until reaching its proper positioning Put the roll pin back in its position NOTICE End of stroke microswitches should be operated before the stop of the stroke of the actuator due to mechanical stops Adjust the relative cams properly Figure 17 Position indicator and pin for microswitches box 21 Section 3 Operation a...

Page 26: ...c cylinder Figure 18 Figure 18 Adjustment of operating time To carry out the adjustment use an adequate Allen wrench and follow these steps Figure 18 Loosen the locknut Screw with a screwdriver the setting screw to increase the operation time Unscrew with a screwdriver the setting screw to decrease the operation time After the adjustment is over screw the locknut The procedure is absolutely genera...

Page 27: ...mes meet the plant requirements and that there are no leaks in the pneumatic connections 3 4 2 Electrical Connections Connect the electrical feed control and signal lines to the actuator by linking them up with the terminal blocks of the electrical components In order to do this the housing covers must be removed without damaging the coupling surfaces the O rings or the gaskets Remove the plugs fr...

Page 28: ...hat the required remote signals valve position air pressure etc are correct 4 Check that the setting of the components of the actuator control unit pressure regulator pressure switches flow control valves etc meet the plant requirements 5 Check that there are not leaks in the pneumatic connections If necessary tighten the nuts of the pipe fittings 6 Remove all rust and in accordance with the appli...

Page 29: ... Tests and Inspections Section 4 Operational Tests and Inspections 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 30: ...tor operates the valve correctly and with the required operating times If the actuator operation is very infrequent carry out a few opening and closing operations with all the existing controls remote control local control emergency controls etc if this is allowed by the conditions of the plant 2 Check that the signals to the remote control desk are correct 3 Check that the air supply pressure val...

Page 31: ...awing and adopting the following procedures WARNING If the actuator can be operated it is essential to take it to fail safe position with the spring totally extended otherwise the actuator should be disassembled from the valve and follow these steps Remove the plug 26 from the cover of the adjustment screw 20 Record the length between end flange and stop setting screw as in Figure 20 Bring the adj...

Page 32: ...ock 14 6 Slide off the piston rod 20 from the head flange 17 7 Disassemble the head flange 17 from the mechanism housing 8 by removing the screws 15 only if the gasket 36 has to be replaced because damaged 5 2 1 1 Seals Replacement Prior to reassemble check that the actuator components are in good conditions and clean Lubricate all the surfaces of the parts which move in contact with other compone...

Page 33: ...maged the piston O ring 42 and the head flange O ring 40 5 Assemble the end flange by centring it on the inside diameter of the tube taking care not to damage the O ring 40 6 Assemble the washers 24 and the nuts 16 onto the tie rods 18 Tighten the nuts to the recommended torque alternating between opposite corners 7 Replace the gasket 25 if damaged and reassemble the hydraulic cylinder 8 Restore a...

Page 34: ...rew 3 Guide block pin 4 Vent valve 5 Sliding block 6 Screw 7 Screw 8 Housing 9 Guide bar 10 Cover gasket 11 Yoke 12 Plug 13 Bushing 14 Guide block 15 Screw 16 Nut 17 Head flange 18 Tie rod Figure 21 ALGAS MHP Single Acting Pneumatic Actuator with Hydraulic Manual Override 30 Maintenance Section 5 Maintenance ...

Page 35: ...End flange 23 Lifting eyelet 24 Spring washer 25 Gasket 26 Screw 27 Nut 28 Nut 29 Stopper bush 30 Container rod 31 Adaptor bush 32 Washer 33 O ring 34 Yoke bushing 35 Retainer ring 36 Gasket 37 Washer 38 Piston rod bushing 39 O ring 40 O ring 41 Guide sliding ring for piston 42 O ring 43 O ring 31 Maintenance Section 5 Maintenance ...

Page 36: ...of the head flange 2 2 Replace the O ring 3 of the end flange 13 For replacement of piston rod seal ring 4 and of the O ring 5 proceed as follows 1 Remove the existing Teflon seal ring 4 and the O ring 5 from their groove 2 Clean the groove carefully and lubricate it with a protective grease film 3 Assemble the new O ring into its groove and lubricate it with a protective grease film 4 Assemble th...

Page 37: ... 2 which are in contact 2 Assemble the head flange and tighten the screws item 26 Figure21 to the recommended torque 3 Clean and lubricate the piston rod item 6 surface particularly that of the bevel with a protective grease film and introduce it into the head flange hole taking care not to damage the Teflon seal ring item 4 the piston rod bevel has to enlarge smoothly the seal ring 4 Carefully cl...

Page 38: ...lated carbon steel 8 2 Guide sliding ring for piston Teflon graphite 9 1 Piston seal ring Teflon NBR rubber 10 4 Tie rod Alloy steel ASTM A320 gr L7 11 1 Stop setting screw Alloy steel 12 1 Cylinder tube Nickel plated carbon steel 13 1 End flange Carbon steel 14 1 Stop setting screw cover Carbon steel 15 4 Spring washer Carbon steel 16 4 Nut Carbon steel ASTM A194 gr 7 17 1 O ring NBR rubber 18 6 ...

Page 39: ...f valve R prevents that the oil pressure delivered by the handpump exceeds the set value so to not damage the valve or the actuator WARNING At the end of hydraulic MANUAL CONTROL CLOSE the stop valve 351 to STOP the valve position To allow the AUTOMATIC CONTROL OPEN the stop valve 351 and bring the distributor lever in the AUTOMATIC CONTROL position 5 3 3 Remote Operation To allow the actuator pne...

Page 40: ...osity index ISO 2909 200 Flash point 105 C Pour point 60 C Specific weight 0 87 Kg dm3 or equivalent Table 12 36 Maintenance Section 5 Maintenance 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 Then to avoid cavitation it is necessary to proceed as follows for the check...

Page 41: ...e nuts of the pipe fittings if necessary The hydraulic oil is in good conditions If necessary and anyway every 3 years substitute the oil into the oil tank by removing the plug item 27 so to drain all the oil and by pouring the new oil into the tank through the hole of dipstick If some dirt or and sludge is found in the oil drained from the tank before filling with new oil the tank disassemble the...

Page 42: ...Figure 23 MAN686 A 38 Maintenance Section 5 Maintenance Pneumatic connection 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 Electric connection ...

Page 43: ...and Maintenance Manual MAN 689 Rev 6 June 2021 Figure 24 Hydraulic Manual Handpump 39 Maintenance Section 5 Maintenance RELIEF VALVE OIL TANK RELIEF VALVE RELIEF VALVE FOR AUTOMATIC OPERATION RELIEF VALVE FOR MANUAL OPERATION ...

Page 44: ... 10 1 Screw Carbon steel 11 1 Plate Carbon steel 12 1 Flange Aluminum 13 4 Screw Carbon steel 14 1 Lever Carbon steel 15 1 Distributor Stainless steel 16 1 O ring Fluorosilicon rubber 17 1 O ring Fluorosilicon rubber 18 1 Nozzle Carbon steel 19 2 Screw Carbon steel 20 3 O ring Fluorosilicon rubber 21 2 O ring Fluorosilicon rubber 22 1 Tank cover Carbon steel 23 2 Tie rod Carbon steel 24 1 Screw Ca...

Page 45: ...inless steel 42 4 Ball Stainless steel 43 2 Spring Spring steel 44 1 Relief valve setting screw Stainless steel 45 2 Spring pin Carbon steel 46 1 Screw Alloy steel 47 1 Spring Stainless steel 48 1 Nut Carbon steel 49 1 Washer Carbon steel rubber 50 2 Washer Carbon steel rubber 51 1 Dipstick Stainless steel 52 1 Plug O ring Stainless steel Fluorosilicon rubber 53 1 Spring Stainless steel 54 1 Screw...

Page 46: ... C ASTM D 566 Product code 001A0065 Infosafe No ACISO GB eng C 42 Maintenance Section 5 Maintenance 5 3 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 ...

Page 47: ...d functioning of quick exhaust valve Call Biffi Italia s r l Customer Service Wear of the valve Replace Actuator too fast High supply pressure Restore Section 1 4 Bad functioning of booster quick exhaust valve Call Biffi Italia s r l Customer Service Wrong calibration of flow regulator valves Restore Section 3 6 Leakages on hydraulic circuits Deterioration and or damage to gaskets Call Biffi Itali...

Page 48: ...umatic supply is discharged from the cylinder by the linear movement generated from the spring releasing It moves actuator and consequently the valve in hits fail safe position If actuator is still mounted onto the valve loosen the threaded connections between valve and actuator screws tie rods nuts Lift the actuator using the proper lifting points see Section 2 3 2 If the actuator needs storage b...

Page 49: ...rbon steel 13 1 Cover Carbon steel 14 1 Guide block pin Alloy steel NOTE Recommended spare parts 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 o...

Page 50: ...oy steel 16 2 Screw Stainless steel 17 2 Yoke supporter washer Ertacetal 18 2 Yoke bushing seat Steel fiberglide 19 2 Guide block pin bushing Steel fiberglide 20 4 Sliding black seat Steel fiberglide 21 2 O ring NBR rubber NOTE Recommended spare parts Cycles perfromed by actuator in a 25 years expected lifetime The minimum performed cycles are guaranteed by Biffi based on service conditions listed...

Page 51: ...el 5 12 Nut Carbon steel 6 6 Tie rod Alloy steel 7 1 Cylinder tube Carbon steel 8 1 Piston rod Alloy steel 9 1 Piston Carbon steel 10 1 End flange Carbon steel 11 1 Lifting eyelet Carbon steel 12 2 Spring washer Carbon steel 13 1 Washer Carbon steel 14 1 Sealing washer PVC 15 1 Nut Carbon steel 16 1 Stop setting screw Carbon steel 17 1 Guide sliding ring for piston Teflon Graphite 18 1 O ring NBR ...

Page 52: ...ing container Carbon steel 6 1 Spring Carbon steel 7 1 Nut Carbon steel 8 1 Shoulder washer Alloy steel 9 1 Rod bushing Steel Bz Teflon 10 1 Guide rod Alloy steel chromium plated 11 1 Spring thrust flange Carbon steel 12 1 Rod bushing Steel bronze Teflon 13 1 Container rod Alloy steel chromium plated NOTE Recommended spare parts Figure 28 Spring cartridge 48 Layouts and Sectional Drawings Section ...

Page 53: ...embly kit Item Qty Description Material 1 4 Screw Alloy steel 2 1 Gasket Fiber 3 1 Side plate Carbon steel 4 2 Gasket Fiber 5 1 Washer Carbon steel 6 1 Adaptor bush Alloy steel 7 1 Adaptor bush Alloy steel 8 6 Washer Carbon steel rubber 9 6 Screw Alloy steel 49 Layouts and Sectional Drawings Section 8 Layouts and Sectional Drawings ...

Page 54: ...r Maintenance Operations Last maintenance operation date in factory on delivery exec by exec by exec by Next maintenance operation date exec by exec by exec by Start up date in factory on delivery on plant 50 Date Report for Maintenance Operations Section 9 Date Report for Maintenance Operations ...

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Page 56: ...publication are presented for information purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or guarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available on request We reserve the right to modify or improve ...