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9. lower the actuator onto the valve insuch a way that the insert bush,assembled on the valve stem, enters

the actuator drive sleeve. Thiscoupling must take place withoutforcing and only with the weight ofthe actuator. When the insert bushhas entered the actuator drive sleeve,check the holes of the valve flange.If they do not meet with the holes ofthe actuator flange or the stud boltsscrewed into them, the actuator drivesleeve must be rotated; feed theactuator cylinder with oil at theproper pressure or actuate themanual override, if existing, untilcoupling is possible

10.tighten the nuts of the connectingstud bolts evenly with the torqueprescribed in the table.The stud bolts must be made ofASTM A320 L 7 steel, the nuts mustbe made of ASTM A194 grade 2 steel

Thread size Recommended tighteningtorque (Nm)

M 8 20M10 40M12 70M14 110M16 160M20 320

M22 420M24 550M27 800M30 1100M33 1400M36 1700

11.if possible, operate the actuator tocheck that it moves the valvesmoothly.

Setting of the angularstroke

It is important that the mechanical stops

of the actuator (and not those of thevalve) stop the angular stroke at bothextreme valve positions (fully open andfully closed), except when this is requiredby the valve operation (e.g. metal seatedbutterfly valves).The setting of the open valve position isperformed by adjusting the travel stopscrew on the left wall of the mechanismhousing, or in the end flange of themanual override, if existing.Proceed as follows:- loosen the lock nut- if the actuator angular stroke is

stopped before reaching the fully openposition, unscrew the stop screw byturning it anticlockwise until the valvereaches the correct position

- tighten the lock nut- if the actuator angular stroke is

stopped beyond the fully open position,

OLGA-H High Pressure Hydraulic Actuatorinstruction and operating manual

Contents may change without notice.

Checks to be carried outon receipt of the actuator

1. If the actuator arrives alreadyassembled onto the valve, the settingof the mechanical stops and of theelectric limit switches (if existing) hasalready been made by the person whoassembled the actuator onto thevalve. If the actuator arrives separatelyfrom the valve, the setting of themechanical stops and of the electriclimit switches (if existing) must bechecked and, if necessary, carried outwhile assembling the actuator onto thevalve.

2. Check that the actuator has not beendamaged during transport.If necessary, repair all damages to thepaint-coat, etc.

3. Check that the model, the serialnumber of the actuator and theperformance data written on thedata-plate are in accordance withthose described on the orderacknowledgement, test certificate anddelivery note.

4. Check that the fitted accessoriescomply with those listed in the orderacknowledgement and the deliverynote.

StorageThe actuators leave the factory inexcellent working conditions and with anexcellent finish (these conditions areguaranteed by an individual inspectioncertificate); in order to maintain thesecharacteristics until the actuator isinstalled on the plant, it is necessary toobserve a few rules and take appropriatemeasures during the storage period.1. Make sure that plugs are fitted in the

oil connections and in the cableentries. The plastic plugs which closethe inlets do not have a weatherproof

function, but are only a means ofprotection against the entry of foreignmatter during transport. If long-termstorage is necessary and especially ifthe storage is outdoor, the plasticprotection plugs must be replaced bymetal plugs, which guarantee acomplete weatherproof protection.If the actuator has been delivered withan empty cylinder, fill it with hydraulicoil compatible with the oil which willsupply the actuator on field.

2. If the actuators are supplied separatelyfrom the valves, they must be placed

onto a wooden pallet so as not todamage the coupling flange to thevalve. In case of long-term storage,the coupling parts (flange, drivesleeve, insert bush) must be coatedwith protective oil or grease.If possible, blank off the flange by a

protection disk.3. In case of long-term storage, it is

advisable to keep the actuators in a

dry place or to provide at least somemeans of weather protection.If a hydraulic control unit is present onthe actuator, it is advisable,ifpossible, to periodically operate theactuator with filtered proper oil. Aftersuch operations all the threadedconnections of the control unit shouldbe carefully plugged by keeping thevalves of the unit filled with as muchoil as possible.

Assembling the actuatoronto the valve

The actuator can be assembled onto thevalve flange either by using the actuatorhousing flange with threaded holes, orby the interposition of an adaptor flangeor a spool piece. The actuator drivesleeve is generally connected to thevalve stem by an insert bush or a stemextension. The assembly position of theactuator, with reference to the valve,

must comply with the plant requirements(cylinder axis parallel or perpendicular tothe pipeline axis). To assemble theactuator onto the valve proceed asfollows:

1. check that the coupling dimensionsof the valve flange and stem, or of therelevant extension, meet the actuatorcoupling dimensions

2. bring the valve to the Closedposition

3. lubricate the valve stem with oil orgrease in order to make the assemblyeasier. Be careful not to pour any of itonto the flange

4. clean the valve flange and removeanything that might prevent a perfectadherence to the actuator flange andespecially all traces of grease, since

the torque is transmitted by friction5. if an insert bush or stem extension

for the connection to the valve stemis supplied separately, assemble itonto the valve stem and fasten it bytightening the proper stop dowels

6. bring the actuator to the Closed

position7. connect a sling to the support points

of the actuator and lift it: make surethe sling is suitable for the actuatorweight. When possible, it is easier toassemble the actuator to the valve ifthe valve stem is in the vertical

position. In this case the actuatormust be lifted while keeping theflange in the horizontal position

8. clean the actuator flange and removeanything that might prevent a perfectadherence to the valve flange andespecially all traces of grease

Copyright by BIFFI Italia. All rights reserved.A !@#$ INTERNATIONAL LTD. COMPANY

BIFFC-0115-EN-9505 1

!#$ flow control

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For electrical connections usecomponents (cable glands, cables,hoses, conduits) which meet the

requirements and codes applicable tothe plant specifications (mechanicalprotection and/or explosionproofprotection). Screw the cable glandstightly into the threaded inlets, so as toguarantee the weatherproof andexplosionproof protection (whenapplicable). Insert the connection cablesinto the electrical enclosures through thecable glands, and connect the cablewires to the terminals according to theapplicable wiring diagram. If conduits areused, it is advisable to carry out theconnection to the electrical enclosuresby inserting hoses so as not to causeany anomalous stress on the housingcable entries. Replace the plastic plugsof the unused enclosure entries by metalones, to guarantee perfect weatherprooftightness and to comply with theexplosionproof protection codes (whereapplicable).Once the connections are completed,check that the controls and signals workproperly.

Start-up

During the start-up of the actuator,

proceed as follows:- check that the pressure and quality ofthe oil supply (type, filtering degree) areas prescribed. Check that the feedvoltage values of the electricalcomponents (solenoid valve coils,microswitches, pressure switches, etc.)are as prescribed

- check that the actuator controls workproperly (remote control, local control,emergency controls, etc.)

- check that the required remote signals(valve position, oil pressure, etc.) arecorrect

- check that the setting of the

components of the actuator controlunit (pressure switches, flow controlvalves, etc.) meet the plantrequirements

- check that there are no leakages in thehydraulic connections. If necessarytighten the nuts of the pipe fittings

- remove all rust and, in accordance withthe applicable painting specifications,repair the paint-coat that has beendamaged during transport, storage orassembly.

Maintenance

Important: before carrying out anymaintenance operation, it is necessary toclose the oil feed line and relieve thepressure from the actuator and from thecontrol unit, to ensure the safety ofmaintenance staff.

a. Routine maintenance

OLGA-H actuators have been designed

to work for long periods in the severest

conditions with no need for maintenance.It is, however, advisable to periodically

check the actuator as follows:

- check that the actuator 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, local,

emergency controls, etc.), if this is

allowed by the plant conditions

- check that the signals to the remote

control desk are correct

- check that the oil supply pressure value

is within the required range- if there is an oil filter on the actuator,

disassemble the cup and wash it;

disassemble the filter: if it is a cleanable

type (metal fibre or wire mesh element),

wash it with nitrate solvent and blow

through it with air. If the filter is a

throw-away type (element based on

inorganic fibres or polyester or paper)

it must be replaced when clogged

- check that the external components of

the actuator are in good conditions

- check all the paint-coat of the actuator.

If some areas are damaged, repair the

paint-coat according to the applicable

specification

- check that there are no leakages in the

hydraulic connections. If necessary

tighten the nuts of the pipe fittings.

b. Special maintenance

If there are oil leaks through the seals or a

malfunction in the mechanical

components, or in case of scheduled

preventive maintenance, the actuator

must be disassembled and seals must be

replaced with reference to the attached

sectional drawing and adopting the

following procedures:

b1. Replacement of cylinder seals

(see sectional drawing)

Disassembly:

- remove the nuts (28) from the

tie rod (19)

- slide off the end flange (26) and

the tube (22)

- remove the screws (2) and the cover (1)

- unscrew the piston rod (18) threaded

end from the adaptor bush (32) of the

guide block (14)

- slide off the piston rod (18) from thehead flange (33)

- disassemble the head flange (33) from

the mechanism housing (8) by removing

the screws (17) only if the gaskets (39)

and (41) have to be replaced because

damaged.



screw the stop screw by turning itclockwise until the valve reaches thecorrect position

- tighten the lock nut.The setting of the closed valve position isperformed by adjusting the travel stopscrew which is in the cylinder end flange.Proceed as follows:- unscrew the plug from the cylinder end

flange- if the actuator angular stroke is

stopped before reaching the fullyclosed position, unscrew the stopscrew by turning it anticlockwise withan Allen wrench until the valve reachesthe correct position

- if the actuator angular stroke isstopped beyond the fully closedposition, screw the stop screw byturning it clockwise until the valvereaches the correct position

- screw the plug into the cylinder endflange.

Preparation for start-up

1. Hydraulic connectionsConnect the actuator to the oil feed andreturn lines with fittings and pipes inaccordance to the plant specifications.They must be sized correctly in order toguarantee the necessary oil flow for theoperation of the actuator, with pressuredrops not exceeding the maximumallowable value. The shape of theconnecting piping must not causeexcessive stress to the inlets of theactuator. The piping must be suitablyfastened so as not to cause excessivestress or loosening of threadedconnections, if the system undergoesstrong vibrations. Every precaution mustbe taken to ensure that anycontaminants which may be present inthe hydraulic pipework to the actuatorare removed to avoid possible damagesto the unit or loss of performance.

The inside of the pipes used for theconnections must be well cleaned beforeuse: wash them with suitable substancesand blow through them with air ornitrogen. The ends of the tubes must bewell deburred and cleaned. Once theconnections are completed, operate theactuator and check that it functionscorrectly, that the operation times meetthe plant requirements and that there areno leakages in the hydraulic connections.

2. Electrical connectionsConnect the electrical feed, control and

signal lines to the actuator, by linkingthem up with the terminal blocks of theelectrical components. In order to dothis, the housing covers must beremoved without damaging the couplingsurfaces, the O-rings or the gaskets.Remove the plugs from the cable entries.


BIFFC-0115-EN-9505 2

Important: before carrying out anymaintenance operation, it is necessaryto close the oil supply line and relievethe pressure from the actuator cylinderand from the control unit, to ensurethe safety of maintenance staff.

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Seals replacementPrior to reassembly check that theactuator components are in good

condition and clean. Lubricate all thesurfaces of the parts which move incontact with other components by arecommended grease (see paragraph b2).If the O-ring must be replaced, removethe existing one from its groove, cleanthe groove carefully and lubricate itwith a protective oil or grease film.Assemble the new O-ring into its grooveand lubricate it with a protective oil orgrease film.

- Replace the O-ring (43) and theback-up ring (42) of the headflange (33).

- Replace the O-ring (43) and theback-up ring (42) of the end flange (26).

To replace the piston rod seal rings (44)proceed as follows:- remove the existing teflon seal ring (44)

with its O-ring from their groove- clean the groove carefully and lubricate

it with a protective oil or grease film- assemble the new O-ring into its

groove and lubricate it with a protectiveoil or grease film

- assemble the new teflon seal ring (44)into the flange groove, on its rubber

O-ring, by bending it: take care that thebending radius is as large as possible toavoid damaging the seal. Then enlargethe seal ring with your fingers so as torestore its round shape: pay attentionnot to utilise any tools which candamage the seal ring.

To replace the piston seal ring (46)proceed as follows:- remove the existing teflon seal ring (46)

and its O-ring from their groove- clean the groove carefully and lubricate

it with a protective oil or grease film- assemble the new O-ring into its groove

and lubricate it with a protective oil orgrease film

- assemble the new teflon seal ring (46)on its rubber O-ring by introducing oneside of it into the groove, then enlarge itwith your fingers so as to fit it into thegroove: take care to enlarge it uniformlywithout any tools which could possiblydamage it. The elastic memory of thekind of teflon the seal ring is made ofallows the ring to shrink back to itsprevious dimension after a short time.

Reassembly:- assemble the new gaskets (39) and (41)

after cleaning the surfaces of the

housing (8), the flange (40) and thehead flange (33), which are in contact

- assemble the head flange (33) andtighten the screws (17) to therecommended torque (see table)

- clean and lubricate the piston rod (18)surface, particularly that of the bevel,with a protective oil or grease film andintroduce it into the head flange hole,taking care not to damage the teflonseal rings (44): the piston rod bevel hasto smoothly enlarge the seal ring

- carefully clean the threaded end of thepiston rod (18) and the threaded hole ofthe adaptor bush (32) of the guide

block (14). Spread some sealantLOCTITE 542, or equivalent, on the rodthreaded end and screw it into theadaptor bush (32) threaded hole, thentighten

- carefully clean the inside of thetube (22) and check that the entiresurface, particularly that of the bevels, isnot damaged. Lubricate with aprotective oil or grease film the tubeinternal surface and the bevels.Slide the tube onto the piston takingcare not to damage the pistonseal ring (46): the tube bevel has to

smoothly compress the seal ring;take care also not to damage the headflange O-ring (43)

- assemble the end flange (26) bycentring it on the inside diameter of thetube, taking care not to damage theO-ring (43)

- assemble the nuts (28) onto thetie rods (19). Tighten the nutsalternating between opposite corners tothe recommended torque (see table)

- restore a generous coating of grease onthe contact surfaces of the yoke (11)and the bushings (35), on the yokegrooves, on the sliding blocks (5), on

guide bar (9)- assemble the new gasket (10) after

cleaning the surfaces of the housing (8)and cover (1)

- lubricate the O-ring (34) with protectiveoil or grease

- assemble the cover (1) and thescrews (2). Tighten the screws to therecommended torque

- carry out a few actuator operations tocheck that movement is regular andthat there is no oil leakage throughthe seals.

b2. Lubrication of mechanismFor normal duty the scotch yokemechanism of the actuator is lubricated

for life. In case of high load and highfrequency of operation it may benecessary to periodically restorelubrication: it is advisable to apply agenerous coating of grease on thecontact surfaces of the yoke andbushings, on the yoke link grooves, onthe sliding blocks, on the guide bar.For this operation it is necessary todisassemble the mechanism cover.In larger actuators the lubrication can beperformed through the inspection holesof the cover after removing the plugs.

The following grease is used by BIFFI forstandard working temperature andsuggested for relubrication:

Manufacturer : AGIP

Type : GR MU/EP

NLGI grade : 1

Worked penetration (dmm) : 325

Drop point ASTM (C) : 185

ISO grade : X1

Equivalent greases:

ESSO BEACON EP1

BP LTX 1

SHELL ALVANIA GREASE R1

For special working conditions and forworking temperatures beyond thestandard range consult BIFFI.

After maintenance operations carryout a few actuator operations tocheck that movement is regular andthat there is no oil leakage throughthe seals.


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Name

Screw

Piston rod

Tie rod

Piston

Stop setting screw

Cylinder tube

Friction Bar

Washer

Plug

End flange

Plug

Nut

Nut

NutStopper bush

Adaptor bush

Item

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

Name

Head flange

O-ring

Yoke bushing

Retainer ring

Flange

Gasket

Gasket

Flange

Gasket

Back-up ring

O-ring

Piston rod seal ring

Guide sliding ring

for pistonPiston seal ring

Item

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.31.

32.

Item

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.15.

16.

Name

Cover

Screw

Guide block pin

Vent valve

Sliding block

Screw

Screw

Housing

Guide bar

Cover gasket

Yoke

Plug

Bushing

Guide blockWasher

Piston rod bushing

1 3 5 7 9 11 13 15 17 19 21 23 25 27

2 4 6 8 10 12 14 16 18 20 22 24 26 28

30

29 31

32

33

AA

B

C

D

F

E

G

A B C D E F G

34 34

36

37 39

40

41 43 45

4342

4644423835



OLGA-H high pressure hydraulic actuator

A.C./

GraficheMalvezzi/3.0

00/12.9

6

Copyright by BIFFI Italia. All rights reserved.A !@#$ INTERNATIONAL LTD COMPANY

BIFFC-0115-EN-95054

OLGA-H-IM-E

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