Alfalaval SBV User manual

TD 451-013
ESE01782-EN7 2016-10
Original manual
Instruction Manual
SBV Sanitary Ball Valve
www.sks-online.com
www.sks-webshop.com

www.sks-online.com
www.sks-webshop.com

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 5
3. Installation .............................................................................................. 6
3.1. Unpacking/delivery ............................................................................... 6
3.2. General installation ................................................................................ 6
3.3. Welding ............................................................................................ 7
3.4. Indication and control equipment (optional extras) ............................................ 8
3.5. Recycling information ............................................................................. 9
4. Operation ............................................................................................... 10
4.1. Operation .......................................................................................... 10
4.2. Fault finding ....................................................................................... 11
4.3. Recommended cleaning ......................................................................... 12
5. Maintenance ........................................................................................... 14
5.1. General maintenance ............................................................................. 14
5.2. Replacement of product wetted seals .......................................................... 15
5.3. Replacement of all seals ......................................................................... 16
6. Technical data ......................................................................................... 20
6.1. Technical data ..................................................................................... 20
7. Parts list/service kits ................................................................................. 21
7.1. SBV Sanitary Ball Valve .......................................................................... 21
7.2. SBV Sanitary Ball Valve for Inch tube ........................................................... 22
7.3. SBV Sanitary Ball Valve for DIN tube ............................................................ 26
3
www.sks-online.com
www.sks-webshop.com

1 EC Declaration of conformity
Revision of Declaration of Conformity 2013-12-03
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
SBV
Type
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- The valve is in compliance with the Pressure Equipment Directive 2014/68/EU and was subjected to the following
assessment procedure Module A. Diameters ≥DN125 may not be used for fluids group 1.
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2016-06-01
Place Date Signature
4
www.sks-online.com
www.sks-webshop.com

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Alwaysreadthemanualbeforeusingthevalve!
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.
2.2 Warning signs
General warning:
Caustic agents:
2.3 Safety precautions
Installation:
Always observe the technical data (see chapter 6 Technical data). !
Always release compressed air after use.
Operation:
Always observe the technical data (see chapter 6 Technical data).
Never touch the valve or the pipelines when processing hot liquids or when sterilizing. !
Always handle lye and acid with great care.
Maintenance:
-Always observe the technical data (see chapter 6 Technical data). !
-Always release compressed air after use.
- The valve must never be hot when servicing it.
- The valve/actuator and the pipelines must never be pressurised when servicing the valve/ actuator.
-Never stick your fingers through the valve ports if the valve is supplied with compressed air.
-Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa
Laval genuine spare parts.
Transportation:
Always secure that compressed air is released.
Always secure that all connections is disconnected before attempt to remove the valve from the installation.
Always drain liquid out of valves before transportation.
Always use predesigned lifting points if defined.
Always secure sufficient fixing of the valve during transportation - if special designed packaging material is available it
must be used.
5
www.sks-online.com
www.sks-webshop.com

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
The items refer to parts list and service kits section.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery:
1. Complete valve.
2. Delivery note.
Step 2
1. Clean the valve for possible packing materials.
2. Inspect the valve for visible transport damage.
3. Avoid damaging air and pipe connections.
3.2 General installation
Step 1
Always read the technical data carefully.
See chapter 6 Technical data
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
For further information on installation of valves, please see Guidelines for installation of valve clusters and other installations,
ESE00041
Step 2
Avoid stressing the valve as this can cause deformation of the
sealing area and malfunction of the valve (leakage or faulty
indication).
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes
- Excessive welding
- Overloading of the pipelines
Fittings:
Ensure that the connections are tight.
Air connection of actuator:
Connect compressed air correctly.
Pay special attention to warnings!
TD451-016_1
6
www.sks-online.com
www.sks-webshop.com

3 Installation
Study the instructions carefully.
3.3 Welding
Step 1
1. Dismantle the flanges in accordance with the instructions in section 4 Operation. Remove seal rings and O-rings.
2, Weld the flanges into the pipe lines. Keep distance B between flanges.
3. If welding both flanges, ensure that the flanges can be moved axially minimum C mm to allow for valve maintenance.
4. Maintain the minimum clearance A so that the actuator or handle can be removed.
5. Assemble the valve in accordance with the instructions in section 4 Operation after the welding.
Size A(mm)(inch)
Manual Actuated
B(mm)
(inch)
C(mm)
(inch)
DN/OD 25
DN 25
317
(12.5)
507
(20.0)
34
(1.3)
30
(1.2)
DN/OD 38
DN 40
325
(12.8)
515
(20.3)
40
(1.6)
30
(1.2)
DN/OD 51
DN 50
335
(13.2)
524
(20.6)
50
(2.0)
30
(1.2)
DN/OD 63.5
DN 65
345
(13.6)
535
(21.1)
56
(2.2)
40
(1.6)
DN/OD 76.1
DN 80
356
(14.0)
546
(21.5)
70
(2.75)
40
(1.6)
DN/OD 101.6
DN 100
406
(16.0)
595
(23.4)
100
(3.9)
40
(1.6)
NOTE: Valves with adapter and ThinkTop: add 200 mm (7.9 inch) to dimension A
Step 2
Pre-use check:
Open and close the valve several times to ensure that the ball
moves smoothly against the seal rings.
Pay special attention to the warnings!
7
www.sks-online.com
www.sks-webshop.com

3 Installation
Study the instructions carefully.
3.4 Indication and control equipment (optional extras)
CAUTION!
The indication and control equipment must be electrically installed by authorized personnel only.
-Inductiveproxi
mity switches:
(See the instructions on the unit).
-ThinkTo p ®:
(See the separate instruction manual).
Manual valves:
Manual valves with optional handle for inductive proximity switches are
designed for the mounting of one or two M12 feedback sensors for open
and/or closed position detection. Feedback sensors should be installed and
adjusted according to the specification on the unit.
Valves with standard actuator:
Valves with standard actuator are prepared for the mounting of one or two
M12 feedback sensors on the position indicator.
Mounting:
1. Remove the red plastic cap for the desired valve position.
2. Tighten the sensor unit gently.
3. Install the unit according to product specification.
8
www.sks-online.com
www.sks-webshop.com

3 Installation
Study the instructions carefully.
Valves with ThinkTop® adapter:
Follow the instructions in the manual.
3.5 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 wear parts in the machine are replaced.
- All metal should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non metal wear parts must be taken care of in agreement with local regulations.
Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be considered and death with in a proper manner. When in doubt, or in the
absence of local regulations, please contact the local Alfa Laval sales company.
9
www.sks-online.com
www.sks-webshop.com

4Operation
Study the instructions carefully and pay special attention to the warnings!
The valve is automatically or manually operated by means of an actuator or a handle.
4.1 Operation
Step 1
Always read the technical data thoroughly.
(see chapter 6 Technical data)
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Step 2
Never touch the valve or the pipelines when processing hot liquids
or when sterilising. Burning
danger!
TD451-022_1
Operation by means of actuator:
Automatic on/off operation by means of compressed air. The
position indicator on the actuator reflects the ball bore position.
In vertical position the valve is open - in horizontal position the
valve is closed.
C: Closed position
P: Position indicator
Operation by means of handle:
1. Press handle arms together while rotating it.
The position of the handle reflects the position of the ball
bore. For correct mounting of handle, please see Step 5.
10
www.sks-online.com
www.sks-webshop.com

4Operation
Pay attention to possible break-down.
Study the instructions carefully.
NC = Normally closed.
NO = Normally open.
4.2 Fault finding
NOTE
Study the maintenance instructions carefully before replacing worn parts - see section 5.1 General maintenance
Problem Cause/result Repair
Internal leakage
(normal wear)
Worn valve seat
Worn flange O-rings Replace the product wetted seals
Internal leakage
(too early)
Worn valve seat
Worn flange O-rings
Many activations
High pressure and/or temperature
Aggressive media
Replace the product wetted seals
Consider selecting another elastomer
sealing material
Change operating conditions
External leakage
(normal wear)
Worn flange O-rings
Worn stem sealing unit Replace all seals
External leakage
(too early)
Damaged or worn flange O-rings
Damaged or worn stem sealing unit
Many activations
High pressure and/or temperature
Aggressive media
Replace all seals
Select another elastomer sealing material
grade
Change operating conditions
Valve cannot be activated or is
difficult to operate
Too low air pressure. Incorrect elastomer
material (swelling)
Check and correct air pressure
Select another elastomer sealing material
grade
Valve is NO (normally open),
should be NC (normally closed) 90° displacement of the actuator
Remove actuator, turn valve into desired
pressureless position and remount
actuator
11
www.sks-online.com
www.sks-webshop.com

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
4.3 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.
Burning
danger!
TD451-022_1
Step 3
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70oC 2. 0.5% by weight HNO3at 70oC (158oF)
1kg(2.2lbs)
NaOH +100 l (26.4 gal) water = Cleaning agent. 0.7l(o.18gal) 53% HNO3
+100 l (26.4 gal)
water = Cleaning agent.
2.2l(0.58gal)
33% NaOH +100 l (26.4 gal)
water =Cleaning agent.
Step 4
1. Avoid excessive concentration of the cleaning agent.
⇒Dose gradually
2. Adjust the cleaning flow to the process.
⇒Sterilisation of milk/viscous liquids
⇒Increase the cleaning flow
3. Always rinse well with clean water after the cleaning.
CAUTION!
The cleaning agents must be stored/disposed of in accordance
with current rules/directives.
Always rinse!
Clean water Cleaning agents
12
www.sks-online.com
www.sks-webshop.com

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
To secure optimum cleaning of the cavity between valve seats and ball during the cleaning cycle, please follow the
recommendations below
In-line cleaning:
Manual valves:
Rotate the ball 20-45° from open position a number of times in the beginning of each cleaning cycle. Adjust duration and
number of cycles to the process.
Valves with air actuator:
Rotatetheball20-45°fromopenpositionanumberoftimesinthebeginningofeachcleaningcycle.
Proposal – initial position: valve open: 1 sec. air release followed by 1 sec. activation. Repeat three times.
Adjust solenoid timing and number of cycles to the process.
Caution: Rotation angles larger than 45° from open position might cause pressure shocks and should therefore be avoided!
Valves with cavity cleaning feature (optional):
The cavity is additionally to be cleaned by connecting the cavity cleaning connections to the cleaning circuit. Caution: To avoid
the risk of mixing product and CIP, the valve cavity should never be cleaned when there is product in the product line.
13
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Maintain the valve and the actuator carefully.
Study the instructions carefully and pay special attention to the warnings!
Always keep service kits in stock. Always useAlfaLavalgenuinespareparts.
5.1 General maintenance
Step 1
Always read the technical data carefully.
See chapter 6 Technical data
Always release compressed air after use.
NOTE
All scrap must be stored/discharged in accordance
with current rules/directives.
Step 2
Never service the valve when it is hot.
The valve/actuator and the pipelines must never be pressurised
when servicing the valve/actuator.
Atmospheric
pressure
required!
Burning danger!
TD451-022_1
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Cutting danger!
Recommended spare parts:
Service kits - see section 7 Parts list/service kits
Order service kits from the service kits list - see section 7 Parts list/service kits
Product wetted seals Valve stem seals
Preventive maintenance Replace after 12 months Replace all seals after 24 month
Maintenance after leakage
(leakage normally starts slowly) Replace at the end of the day Replace by the end of the day
Planned maintenance
-Reg
ular inspection for leakage
and smooth operation
-Kee
p a record of the valve
-Us
e the statistics for planning of
inspections
-Reg
ular inspection for leakage
and smooth operation
-Kee
p a record of the valve
-Us
e the statistics for planning of
inspections
NOTE! The actuator is maintenance-free.
14
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section - see section 7 Parts list/service kits.
5.2 Replacement of product wetted seals
Step 1
1. Study the instructions carefully. The items refer to the parts list and service kits section. Service kit: 2 pcs. valve seat (5), 2
pcs. O-ring (6), 2. pcs. O-ring (7).
2. Loosen and remove flange screws (8) and remove valve from pipe line (be careful not to drop the ball if the valve is in
closed position).
3. Remove ball (3) and check for excessive wear or damage.
4. Remove valve seat (5) and O-rings (6), (7) from flange (2).
Step 2
1. Insert new O-rings (6), (7) and valve seat (5) in flange (2).
2. CAUTION! NC valves: Ball should be turned to “closed” position before fitting the actuator without compressed air (be
careful not to drop the ball).
NO valves: Ball should be turned to “open” position before fitting acuator.
3. Insert valve body (1) between flanges (2).
4. Tighten screws (8) until metallic stop.
15
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
5.3 Replacement of all seals
Disassembly of valve:
Step 1
Release all compressed air (actuated valves only).
Step 2
1. Loosen and remove flange screws (8) and remove valve from
pipe line (be careful not to drop the ball if the valve is in closed
position.)
2. Remove ball (3) and check for excessive wear or damage.
3. Remove valve seat (5) and O-rings (6), (7) from flange (2).
Release all compressed air (actuated valves only).
TD451-027_1
Step 3
Actuated valves
1. Loosen screws (18) and remove actuator (20) and coupling (17).
2. Loosen screws (16) and remove bonnet (19)
Manual valves
1. Loosen screw (26) and remove handle (25).
2. Loosen screws (23) and remove top plate (24).
Step 4
1. Remove slide bearing (14) and spring (13).
2. Remove stem (4) and sliding ring (9) through the valve
body (1).
3. Remove stem gasket unit (10), (11) and (12).
TD451-002_1
14
13
12
11
10
9
4
16
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Step 5
Reassembly of valve:
Place the new sliding ring (9) on stem (4) and mount stem unit in
valve body (1)
Step 6
Insert new gasket unit (10), (11) and (12) in valve body.
Use the mounting tool and be careful not to damage the
stem gaskets.
TD451-002_1
14
13
12
11
10
9
4
Step 7
Place spring (13) and new slide bearing (14) on stem (4).
TD 451-032
17
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Step 7a
Actuated valves
1. Mount bonnet (19) on valve body (1) with screws (16)
2. Align bonnet (19) with the two pins (15).
Step 7b
Manual valves
1. Mount top plate (24) on valve body (1) with screws (23)
2. Align top plate (24) with the two pins (15).
Step 8
Fit ball
CAUTION!
-NC valves: Ball should be turned to “closed” position before
fitting the actuator without compressed air (be careful not to
drop the ball).
-NO valves: Ball should be in “open” position before fitting
actuator.
18
www.sks-online.com
www.sks-webshop.com

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Step 9
Actuated valves:
Actuated valves
1. Mount coupling (17) and actuator (20) on bonnet (19) with
screws (18)
2. Align position indicators on actuator and stem.
Manual valves
1. Mount handle (25) on stem (4) with screw (26)
2. Align handle with position indicator on stem.
Step 10
1. Align handle with position indicator on stem.
2. Insert valve body (1) between flanges (2).
3. Insert valve body (1) between flanges (2).
4. Open and close the valve several times to ensure proper
operation.
TD451-027_1
19
www.sks-online.com
www.sks-webshop.com

6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.
NC = Normally closed.
NO = Normally open.
6.1 Technical data
A precision made ball with a bore is positioned inside the valve body between two flanges and two PTFE valve seats. A 90°
rotation of the valve stem is transferred to the ball and thereby opening or closing the valve.
A special selected PTFE material grade secures long lifetime of the product wetted seals.
Reliable valve stem sealing is achieved by the use of spring loaded and self adjusting seal rings. SBV is operated by a
pneumatic actuator or manually operated by means of a handle with lockable positions. The valve is assembled with screws for
easy inspection and maintenance.
Valve
Max. product pressure 1600 kPa (10 bar) (232 PSI)
Max. recommended pressure during activation 600 kPa (6 bar)
Min. product pressure Full vacuum
Temperature range -10oCto+130
oC(14 oto 266°F) (EPDM).
Air consumption ø104: 0.5 Nl Air consumption ø104: 0.5 Nl
Air consumption ø129: 0.75 Nl Air consumption ø129: 0.75 Nl
Max. sterilisation temperature, short time + 150° C (302° F)
Actuator
Operating pressure 600 - 1000 kPa (6 - 10 bar) (87 - 145 PSI)
Temperature range +4°Cto+60
°C (39.2 to 140 F)
Materials
Product wetted steel parts AISI 316L
Other steel parts AISI 304
Surface quality, product wetted parts Ra < 0.8µm
External surface finish Semi bright
External surface finish, actuator Semi bright (brushed)
Product wetted seals PTFE, EPDM
Other seals PTFE, NBR
Weight (kg)
Inch tubes DIN tubes
Size DN/OD
25
DN/OD
28
DN/OD
51
DN/OD
63.5
DN/OD
76.1
DN/OD
101.6
DN
25
DN
40
DN
50
DN
65
DN
80
DN
100
Manual (kg) 2.3 3.4 4.8 713.5 27 2 3.1 4.5 6.4 12.3 24
Actuated (kg) 6.7 7.8 9.2 11.4 17.9 35.8 6.4 7.5 8.9 10.8 17.9 32
ThinkTop®
adapter (kg) 8.6 9.7 11.1 13.3 19.8 37.7 8.3 9.4 10.8 12.7 19.8 34.7
Noise
One meter away from - and 1.6 meter above the exhaust the noise level of a valve actuator will be approximately 77db(A) without
noise damper and approximately 72 db (A) with damper - Measured at 7 bars air-pressure.
20
www.sks-online.com
www.sks-webshop.com