ALGA Pneumatic Actuator

instruction and operating manual

!@#$ flow control

Checks to be carried out 3. In case of long-term storage, it is such a way that the insert bush,
on receipt of the actuator advisable to keep the actuators in a assembled on the valve stem, enters
dry place or to provide at least some the actuator drive sleeve. This
1. If the actuator arrives already means of weather protection. coupling must take place without
assembled onto the valve, the setting If possible, it is also advisable to forcing and only with the weight of
of the mechanical stops and of the periodically operate the actuator with the actuator. When the insert bush
electric Iimit switches (if existing) has filtered, dehydrated and lubricated air; has entered the actuator drive sleeve,
already been made by the person who after such operations all the threaded check the holes of the valve flange.
assembled the actuator onto the connections of the actuator and the If they do not meet with the holes of
valve. If the actuator arrives separately valves of the control panel (if present) the actuator flange or the stud bolts
from the valve, the setting of the should be carefully plugged. screwed into them, the actuator drive
mechanical stops and of the electric sleeve must be rotated; feed the
limit switches (if existing) must be Assembling the actuator actuator cylinder with air at the
checked and, if necessary, carried out onto the valve proper pressure or actuate the
while assembling the actuator onto the manual override, if existing, until
valve. The actuator can be assembled onto the coupling is possible
2. Check that the actuator has not been valve flange either by using the actuator 10.tighten the nuts of the connecting
damaged during transport. housing flange with threaded holes, or stud bolts evenly with the torque
If necessary, repair all damages to the by the interposition of an adaptor flange prescribed in the table. The stud
paint-coat, etc. or a spool piece. The actuator drive bolts must be made of
3. Check that the model, the serial sleeve is generally connected to the ASTM A320 L 7 steel, the nuts must
number of the actuator and the valve stem by an insert bush or a stem be made of ASTM A194 grade 2 steel
performance data written on the extension. The assembly position of the
data-plate are in accordance with actuator, with reference to the valve,
must comply with the plant requirements Thread size Recommended tightening
those described on the order
(cylinder axis parallel or perpendicular to torque (Nm)
acknowledgement, test certificate and
delivery note. the pipeline axis). To assemble the
M 8 20
4. Check that the fitted accessories actuator onto the valve proceed as M10 40
comply with those listed in the order follows: M12 70
acknowledgement and the delivery 1. check that the coupling dimensions M14 110
note. of the valve flange and stem, or of the M16 160
relevant extension, meet the actuator M20 320
M22 420
coupling dimensions
Storage 2. bring the valve to the “Closed”
M24 550
M27 800
The actuators leave the factory in position M30 1100
excellent working conditions and with an 3. lubricate the valve stem with oil or M33 1400
excellent finish (these conditions are grease in order to make the assembly M36 1700
guaranteed by an individual inspection easier. Be careful not to pour any of it
11.if possible, operate the actuator to
certificate); in order to maintain these onto the flange
check that it moves the valve
characteristics until the actuator is 4. clean the valve flange and remove
smoothly.
installed on the plant, it is necessary to anything that might prevent a perfect
observe a few rules and take appropriate adherence to the actuator flange and
measures during the storage period. especially all traces of grease, since
Setting of the angular
1. Make sure that plugs are fitted in the the torque is transmitted by friction stroke
air connections and in the cable 5. if an insert bush or stem extension for It is important that the mechanical stops
entries. The plastic plugs which close the connection to the valve stem is of the actuator (and not those of the
the inlets do not have a weatherproof supplied separately, assemble it onto valve) stop the angular stroke at both
function, but are only a means of the valve stem and fasten it by extreme valve positions (fully open and
protection against the entry of foreign tightening the proper stop dowels fully closed), except when this is required
matter during transport. If long-term 6. bring the actuator to the “Closed” by the valve operation (e.g. metal seated
storage is necessary and especially position butterfly valves).
if the storage is outdoor, the plastic 7. connect a sling to the support points The setting of the open valve position is
protection plugs must be replaced by of the actuator and lift it: make sure performed by adjusting the travel stop
metal plugs, which guarantee a the sling is suitable for the actuator screw in the left wall of the mechanism
complete weatherproof protection. weight. When possible, it is easier to housing, or in the end flange of the
2. If the actuators are supplied separately assemble the actuator to the valve if manual override, if existing.
from the valves, they must be placed the valve stem is in the vertical The setting of the closed valve position is
onto a wooden pallet so as not to position. In this case the actuator performed by adjusting the travel stop
damage the coupling flange to the must be lifted while keeping the screw in the cylinder end flange.
valve. In case of long-term storage, flange in the horizontal position Proceed as follows:
the coupling parts (flange, drive 8. clean the actuator flange and remove - loosen the lock nut
sleeve, insert bush) must be coated anything that might prevent a perfect - if the actuator angular stroke is
with protective oil or grease. adherence to the valve flange and stopped before reaching the end
If possible, blank off the flange by a especially all traces of grease position (fully open or closed), unscrew
protection disk. 9. lower the actuator onto the valve in the stop screw by turning it

Contents may change without notice. © Copyright by BIFFI Italia. All rights reserved. BIFFC-0067-EN-9505 1
A !@#$ INTERNATIONAL LTD. COMPANY
 ALGA Pneumatic Actuator
instruction and operating manual

anticlockwise, until the valve reaches protection and/or explosionproof work for long periods in the severest
the correct position. When unscrewing protection). Screw the cable glands conditions with no need for maintenance.
the stop screw, keep the lock nut still tightly into the threaded inlets, so as to It is, however, advisable to periodically
with a wrench so that the sealing guarantee the weatherproof and check the actuator as follows:
washer does not withdraw together explosionproof protection (when - check that the actuator operates the
with the screw applicable). Insert the connection cables valve correctly and with the required
- tighten the lock nut into the electrical enclosures through the operating times. If the actuator
- If the actuator angular stroke is cable glands, and connect the cable operation is very infrequent, carry out a
stopped beyond the end position (fully wires to the terminals according to the few opening and closing operations with
open or closed), screw the stop screw applicable wiring diagram. If conduits are all the existing controls (remote, local,
by turning it clockwise until the valve used, it is advisable to carry out the emergency controls, etc.), if this is
reaches the correct position connection to the electrical enclosures allowed by the plant conditions
- tighten the lock nut. by inserting hoses so as not to cause - check that the signals to the remote
anomalous stress on the housing cable control desk are correct
Preparation for start-up entries. Replace the plastic plugs of the - check that the air supply pressure value
unused enclosure entries by metal ones, is within the required range
1. Pneumatic connections to guarantee perfect weatherproof - if there is an air filter on the actuator,
Connect the actuator to the pneumatic tightness and to comply with the bleed the condensed water
feed line with fittings and pipes in explosionproof protection codes (where accumulated in the cup by opening the
accordance to the plant specifications. applicable). drain cock. Disassemble the cup
They must be sized correctly in order to Once the connections are completed, periodically and wash it with soap and
guarantee the necessary air flow for the check that the controls and signals work water; disassemble the filter: if this is
operation of the actuator, with pressure properly. made of a sintered cartridge, wash it
drops not exceeding the maximum with nitrate solvent and blow through it
allowable value. The shape of the Start-up with air. If the filter is made of cellulose,
connecting piping must not cause it must be replaced when clogged
excessive stress to the inlets of the During the start-up of the actuator,
proceed as follows: - check that the external components of
actuator. The piping must be suitably the actuator are in good conditions
fastened so as not to cause excessive - check that the pressure and quality of
the air supply (filtering degree, - check all the paint-coat of the actuator.
stress or loosening of threaded If some areas are damaged, repair the
dehydration) are as prescribed. Check
connections, if the system undergoes paint-coat according to the applicable
that the feed voltage values of the
strong vibrations. specification
electrical components (solenoid valve
Every precaution must be taken to - check that there are no leaks in the
coils, microswitches, pressure
ensure that any solid or liquid pneumatic connections. If necessary
switches, etc.) are as prescribed
contaminants which may be present in tigthten the nuts of the pipe fittings.
- check that the actuator controls work
the pneumatic pipework to the actuator
properly (remote control, local control, b. Special maintenance
are removed to avoid possible damages
emergency controls, etc.) If there are air leaks in the pneumatic
to the unit or loss of performance.
- check that the required remote signals cylinder or a malfunction in the
The inside of the pipes used for the
(valve position, air pressure, etc.) are mechanical components, or in case of
connections must be well cleaned before
correct scheduled preventative maintenance, the
use: wash them with suitable substances - check that the setting of the
and blow through them with air or actuator must be disassembled and seals
components of the actuator control must be replaced with reference to the
nitrogen. The ends of the tubes must be unit (pressure regulators, pressure
well deburred and cleaned. sectional drawing (page 4) and adopting
switches, flow control valves, etc.) the following procedures:
Once the connections are completed, meet the plant requirements
operate the actuator and check that it - check that there are no leaks in the b1. Replacement of cylinder seals
functions correctly, that the operation pneumatic connections. If necessary (see sectional drawing)
times meet the plant requirements and tighten the nuts of the pipe fittings
that there are no leaks in the pneumatic - remove all rust and, in accordance with Disassembly:
connections. the applicable painting specifications, - remove the nuts (16) and the
repair paint-coat that has been washers (24) from the tie rod (18) at
2. Electrical connections the end flange (22) side
damaged during transport, storage or
Connect the electrical feed, control and - slide off the end flange (22) and the tube
assembly.
signal lines to the actuator, by linking (19)
them up with the terminal blocks of the Maintenance - remove the screws (2) and the cover (1)
electrical components. In order to do - unscrew the piston rod (20) threaded
this, the housing covers must be Important: before carrying out any end from the adaptor bush (30) of
removed without damaging the coupling maintenance operation, it is necessary guide block (14)
surfaces, the O-rings or the gaskets. to close the pneumatic feed line and - slide off the piston rod (20) from the
Remove the plugs from the cable entries. exhaust the pressure from the actuator head flange (17)
For electrical connections use cylinder and from the control unit, to - disassemble the head flange (17)
components (cable glands, cables, ensure the safety of maintenance staff. from the mechanism housing (8) by
hoses, conduits) which meet the removing the screws (15) only if the
requirements and codes applicable to a. Routine maintenance gasket (36) has to be replaced
the plant specifications (mechanical ALGA actuators have been designed to because damaged.

Contents may change without notice. © Copyright by BIFFI Italia. All rights reserved. BIFFC-0067-EN-9505 2
A !@#$ INTERNATIONAL LTD. COMPANY
 ALGA Pneumatic Actuator
instruction and operating manual

Seals replacement Reassembly: b2. Lubrication of mechanism

Prior to reassembly check that the - assemble the new gasket (36) after For normal duty the scotch yoke
actuator components are in good cleaning the surfaces of housing (8) mechanism of the actuator is lubricated
condition and clean. Lubricate all the and head flange (17), which are in “for life”. In case of high load and high
surfaces of the parts which move in contact frequency of operation it may be
contact with other components by a - assemble the head flange (17), necessary to periodically restore
recommended grease (see paragraph replace the washers (37) if damaged, lubrication: it is advisable to apply a
b2). If the O-ring must be replaced, tighten the screws (15) to the generous coating of grease on the
remove the existing one from its groove, recommended torque (see table) contact surfaces of the yoke and
clean the groove carefully and lubricate it - lubricate the piston rod (20) surface bushings, on the yoke link grooves, on
with a protective oil or grease film. with a protective oil or grease film and the sliding blocks, on the guide bar.
Assemble the new O-ring into its groove introduce it into the head flange hole, For this operation it is necessary to
and lubricate it with a protective oil or taking care not to damage the disassemble the mechanism cover. In
grease film. O-ring (39). Carefully clean the threaded large actuators the lubrication can be
end of piston rod (20) and the threaded performed through the inspection holes
- Replace the O-rings (39 and 40) of hole of the adaptor bush (30) of the of the cover after removing the plugs.
the head flange (17). guide block (14). Spread some sealant
- Replace the O-ring (42) and the LOCTITE 542, or equivalent, on the rod The following grease is used by BIFFI for
guide sliding ring (41) of the piston. threaded end and screw it into the standard working temperature and
- Replace the O-ring (40) of the end adaptor bush (30) threaded hole, then suggested for relubrication:
flange (22). tighten
- carefully clean the inside of the Manufacturer : AGIP
If the sealing washer (43) has to be tube (19) and check that the entire Type : GR MU/EPI
replaced, measure the protrusion of the surface, particularly that of the bevels, is NLGI grade :1
stop screw (26) with reference to the not damaged. Lubricate with a Worked penetration (dmm) : 325
end flange (22) surface, so as to be protective oil or grease film the tube
Drop point ASTM (°C) : 185
able to easily restore the setting of the internal surface and the bevels. Slide
actuator mechanical stop in the closed the tube onto the piston taking care not ISO grade : X1
valve position, once the maintenance to damage the piston O-ring (42) and Equivalent greases:
procedures have been completed. the head flange O-ring (40) ESSO BEACON EP1
- Loosen the lock nut (25) and unscrew - assemble the end flange by centering BP LTX 1
the stop screw (26) until it is removed it on the inside diameter of the tube, SHELL ALVANIA GREASE R1
together with the nut (25), the washer taking care not to damage the
(44) and the sealing washer (43). O-ring (40)
- Remove the sealing washer (43) from - assemble the washers (24) and the For special working conditions and for
the stop screw (26). Carefully clean nuts (16) onto the tie rods (18). working temperatures beyond the
and lubricate the stop screw thread Tighten the nuts to the recommended standard range consult BIFFI.
and the surface of the end flange area, torque (see table), alternating between
on which the sealing washer is. opposite corners After maintenance operations carry out
- Screw the new sealing washer onto - restore a generous coating of grease on a few actuator operations to check that
the stop screw until it touches the the contact surfaces of the yoke (11) movement is regular and that there are
nut (25). and the bushings (33), on the yoke no air leaks through the seals.
- Assemble the washer (44) onto the grooves, on the sliding blocks (5), on
sealing washer (43). the guide bar (9)
- Screw the stop screw into the - assemble the new gasket (10) after
threaded hole of the end flange until it cleaning the surfaces of the housing (8)
reaches its original position (the same and cover (1)
protrusion with reference to the flange - lubricate the O-ring (32) with protective
surface). oil or grease
- Check that the sealing washer (43) - assemble the cover (1) and the
and the washer (44) are in contact screws (2). Tighten the screws to the
with the flange surface. recommended torque
- Tighten the lock nut (25). - carry out a few actuator operations to
check that movement is regular
and that there are no air leaks through
the seals.

Contents may change without notice. © Copyright by BIFFI Italia. All rights reserved. BIFFC-0067-EN-9505 3
A !@#$ INTERNATIONAL LTD. COMPANY
 ALGA Pneumatic Actuator
instruction and operating manual

1 3 5 7 9 11 13 15 16 18 20 22 24 26
2 4 6 8 10 12 14 17 19 21 23 25

C F G

E
B
A A H

28 30
27 29 31

32 32 35 36 38 40 42 44

ALGA-IM-E
33 34 36 37 39 41 43

A B C D E F G H

ALGA pneumatic actuator

Item Name Item Name Item Name

1. Cover 16. Nut 31. Washer

2. Screw 17. Head flange 32. O-ring
3. Guide block pin 18. Tie rod 33. Yoke bushing
4. Vent valve 19. Cylinder tube 34. Retainer ring
5. Sliding block 20. Piston rod 35. Flange
A.C./Grafiche Malvezzi/1.500/01.98

6. Travel stop screw 21. Piston 36. Gasket

7. Screw 22. End flange 37. Washer
8. Housing 23. Lifting eyelet 38. Piston rod bushing
9. Guide bar 24. Spring washer 39. O-ring
10. Cover gasket 25. Nut 40. O-ring
11. Yoke 26. Travel stop screw 41. Piston guide sliding ring
12. Plug 27. Nut 42. O-ring
13. Bushing 28. Nut 43. Sealing washer
14. Guide block 29. Stop screw bush 44. Washer
15. Screw 30. Adaptor bush

4 © Copyright by BIFFI Italia. All rights reserved. BIFFC-0067-EN-9505 Contents may change without notice.
A !@#$ INTERNATIONAL LTD. COMPANY