Alfalaval Pressure Relief Valve User manual

2900-0109
ESE02426-EN1 2013-04
Original manual
Instruction Manual
Unique Sampling Valve - Accessories - Pressure Relief Valves

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Safety .................................................................................................... 4
1.1. Important information ............................................................................. 4
1.2. Warning signs ..................................................................................... 4
1.3. Safety precautions ................................................................................ 5
2. Installation .............................................................................................. 6
2.1. Unpacking/delivery ............................................................................... 6
2.2. General installation ................................................................................ 6
2.3. Recycling information ............................................................................. 7
3. Operation ............................................................................................... 8
3.1. Operation .......................................................................................... 8
3.2. Troubleshooting ................................................................................... 9
3.3. Recommended cleaning ......................................................................... 10
4. Maintenance ........................................................................................... 11
4.1. General maintenance ............................................................................. 11
4.2. Dismantling the valve ............................................................................. 12
4.3. Assembly of valve ................................................................................. 12
5. Product information ................................................................................... 13
5.1. Technical data ..................................................................................... 13
5.2. Product range ..................................................................................... 14
6. Parts list and service kits ............................................................................ 16
6.1. Pressure Relief Valve - sizes 4 and 10 .......................................................... 16
6.2. Pressure Relief Valve - size 25 ................................................................... 18
3

1 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
1.1 Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
1.2 Warning signs
General warning:
Caustic agents:
4

1 Safety
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the valve are avoided.
1.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 6 Parts list and service kits)
Always release compressed air after use.
Never touch the moving parts if the actuator is supplied with compressed air.
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never dismantle the valve with the valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Operation:
Never dismantle the valve with the valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always read the technical data thoroughly. (See chapter 6 Parts list and service kits)
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never touch the moving parts if the actuator is supplied with compressed air.
Always rinse well with clean water after cleaning.
Always handle lye and acid with great care.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Parts list and service kits)
Always release compressed air after use.
Never servicethevalvewhenitishot.
Never service the valve with the valve and pipelines under pressure.
Never stick your fingers through the valve ports if the actuator is supplied with compressed air.
Never touch the moving parts if the actuator is supplied with compressed air.
Transportation:
Always ensure that compressed air is released.
Always ensure that all connections is disconnected before attempt to remove from the installation.
Always drain liquid out of valves before transportation.
Always use pre-designed lifting points if available.
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available, it
must be used.
5

2 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The items refer to the parts list and service kits section.
2.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Valve
2. Instruction manual
Step 2
Remove possible packing materials from the valve/valve parts.
Inspect the valve/valve parts for visible transport damage.
Avoid damaging the valve/valve parts.
2.2 General installation
Always read the technical data thoroughly.
See chapter 5.1 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Mount the Pressure Relief Valve on the lower connection as shown below.
1. Push down and hold the safety button
2. Pull back the handle
3. Mount the Pressure Relief Valve on the lower connection
on the Sampling Valve
1
2
3
2900-0110
6

2 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The items refer to the parts list and service kits section.
2.3 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance, oil and wearing parts in the machine are replaced.
- All metal parts should be sent for material recycling.
- Worn or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wearing parts must be dealt with in accordance with local regulations.
•Scrapping
- At the end of use, the equipment should be recycled according to the relevant, local regulations. As well as the equipment
itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt,
or in the absence of local regulations, please contact your local Alfa Laval sales company.
7

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
3.1 Operation
Always read the technical data thoroughly.
See chapter 5.1 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Danger of burns!
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
The Pressure Relief Valve is used to ensure that the temperature is at the right level when performing steam sterilisation on
the Sampling Valve.
1. Single Seat: Set the actuator to closed position
Double Seat: Set the actuator to seat lift/steam position.
2. Mount a hose on the steam outlet nozzle to ensure that the
steam is led away.
3. Supply steam to the upper connection of the Sampling Valve
(2.5-3.5 bar)
4. When steam appears from the steam outlet nozzle, then
leave the steam on for 2 minutes.
5. Shut off the steam supply.
6. Pull the quick release handle to ensure that no steam
pressure is present in the sampling valve.
7. The Sampling Valve is now clean and ready to take a sample.
We recommend that the Sampling Valve is steam sterilised
after a sample has been taken.
A. Steam inlet
B. Non Return Valve
C. Pressure Relief Valve
D. Quick release of steam
E. Steam outlet nozzle.
Be careful! 2900-0111
A
B
C
D
E
8

3Operation
Study the instructions carefully and pay special attension to the warnings.
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
3.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause Repair
O-ring worn or damaged Replace o-ring
Steam leakage Membrane worn or damaged Replace membrane
Steam pressure too low Ensure that the supplied steam pressure
is above 2 bars
No steam at nozzle outlet
Blockage of the Pressure Relief Valve Inspect the Pressure Relief Valve and
ensure that nothing is obstructing the
valve
Steam pressure too low Ensure the the supplied steam pressure
is above 2 bars
Steam temperature is below 120 °C at
the Sampling Valve The Pressure Relief Valve opens too early
Inspect the Pressure Relief Valve and
ensure that nothing is obstructing the
valve
9

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
3.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
Never touch the valve or the pipelines when sterilising.
Danger of burns!
Step 3
Pay special attention to the warnings!
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70 °C
1kgNaOH +100 l water =Cleaning agent.
2.2 l
33% NaOH +100 l water =Cleaning agent.
2. 0.5% by weight HNO3at 70 °C
0.7 l
53% HNO3+100 l water = Cleaning agent.
Step 5
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. Always rinse well with clean water after cleaning.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agents
10

4 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Check the valve for smooth operation after service.
4.1 General maintenance
Maintenance Action
Maintenance after leakage - Replace o-ring
- Replace membrane seal
Regular inspection for leakage and smooth operation
Keep a record of the valve
Use the statistics for inspection planning
Planned maintenance
Replace after leakage
Lubrication Klüber Paraliq GTE703 or similar
Recommended spare parts
Service kits (see section 6 Parts list and service kits)
11

4 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Check the valve for smooth operation after service.
4.2 Dismantling the valve
Step 1
1. Unscrew the socket hex screw (4 mm).
2900-0112
Step 2
Unscrew the nut.
A. Membrane
B. Nut 2900-0113
A
B
4.3 Assembly of valve
Follow the reverse order of chapter 4.2 Dismantling the valve
12

5 Product information
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
5.1 Technical data
Attention!
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never service the valve when it is hot.
Danger of burns!
Technical data
Max. working temperature 140 °C
Opening pressure 200 kPa (2 bar absolute)
Weight: 0.1 kg
Materials
Steel parts 1.4301 (304)
Plastic parts PA 6.6 30% GF
O-ring and membrane EPDM
Spare parts
Sealing kit See section 6 Parts list and service kits
2900-0114
13

5 Product information
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
5.2 Product range
This is the standard Pressure Relief Valve range that is compatible with the Unique Sampling Valve.
Pressure Relief Valve for Sampling Valve sizes 4 and 10 Pressure Relief Valve for Sampling Valve size 25
2900-0114 2900-0115
14

.
15

6 Parts list and service kits
Study the instructions carefully and pay special attention to the warnings!
6.1 Pressure Relief Valve - sizes 4 and 10
19
21
22
17
18
10
16
20
11
12
14
9
15
13
8
7
6
5
4
3
2
1
2900-0116
16

6 Parts list and service kits
Study the instructions carefully and pay special attention to the warnings!
Parts list
Pos. Qty Denomination
11
Screw
21Handle
31Nut
41
Spring housing
51Spring
61Stem
71Guide for membrane
8▲1Membrane
91Cover
10 1Push button
11 1 Spring
12 1Safety pawl
13 1 Valve body
14 ▲1O-ring
15 1 Nozzle
16 ▲1O-ring
17 3Ball
18 1 Spring
19 1 Handle
20 1Lock ring
21 1Handle insert
22 1 Lock ring
Service kits
Denomination
▲Service kit ...................................................... 9611-9243-10
17

6 Parts list and service kits
Study the instructions carefully and pay special attention to the warnings!
6.2 Pressure Relief Valve - size 25
19
21
17
20
18
10
22
11
16
12
14
13
9
15
8
7
6
5
4
3
2
1
2900-0117
18

6 Parts list and service kits
Study the instructions carefully and pay special attention to the warnings!
Parts list
Pos. Qty Denomination
11
Screw
21Handle
31Nut
41
Spring housing
51Spring
61Stem
71Guide for membrane
8▲1Membrane
91Cover
10 1Push button
11 1 Spring
12 1Safety pawl
13 1 Valve body
14 ▲1O-ring
15 1 Nozzle
16 ▲1O-ring
17 6Ball
18 1 Spring
19 1 Handle
20 1Lock ring
21 1Handle insert
22 1 Lock ring
Service kits
Denomination
aService kit ...................................................... 9611-9243-11
19

How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.