Alfalaval SMP-BC User manual

TD 430-147_1
ESE02255-EN7 2016-06
Original manual
Instruction Manual
SMP-BC Sanitary Mixproof Valve

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 ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. Recycling .......................................................................................... 8
3.3. Recommended auxiliary equipment (DN125/150) ............................................. 9
3.4. General installation ................................................................................ 10
3.5. Welding ............................................................................................ 11
4. Operation ............................................................................................... 14
4.1. Operation .......................................................................................... 14
4.2. Fault finding ....................................................................................... 14
4.3. Recommended cleaning ......................................................................... 15
4.4. Cleaning equipment (optional extra) ............................................................ 18
5. Maintenance ........................................................................................... 20
5.1. General maintenance ............................................................................. 20
5.2. Dismantling of valve .............................................................................. 22
5.3. Assembly of valve ................................................................................. 24
5.4. Dismantling of actuator ........................................................................... 25
5.5. Assembly of actuator ............................................................................. 27
5.6. Replacement of plug seals ....................................................................... 29
6. Technical data ......................................................................................... 33
6.1. Technical data ..................................................................................... 33
7. Parts list and service kits ............................................................................ 34
7.1. Drawings ........................................................................................... 34
7.2. SMP-BC stop valve ............................................................................... 36
7.3. SMP-BC change-over valve ..................................................................... 38
7.4. SMP-BC stop valve - size DN125/DN150 ..................................................... 42
7.5. Tools for plug seals ............................................................................... 44
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Sanitary Mixproof Valve
Designation
SMP-BC PN10
Type
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
- 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
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damagetothevalveareavoided.
2.1 Important information
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: Cutting danger:
5

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Always release compressed air after use
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Operation:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Always release compressed air after use
Never touch the clip assembly or the actuator piston rod when the actuator is supplied with compressed air
Never touch the valve or the pipelines when processing hot liquids or when sterilizing
Always keep the cleaning pressure lower than the product pressure
Never throttle the outlet of the detecting valve
Always handle lye and acid with great care
Maintenance:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Always release compressed air after use
Always remove the CIP connections before service
Never servicethevalvewhenitishot
Never service the valve with valve and pipelines under pressure
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
Transportation:
Always ensure that compressed air are released
Always ensure that all connections is disconnected before attempting to remove the valve from the installation
Always drain liquid out of valves before transportation
Always use predesigned lifting points if defined
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available, it
must be used
6

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Stop valve: With one valve body. Change-over valve: With three valve bodies.
CIP = Cleaning In Place
3.1 Unpacking/delivery
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, standard or three-bodied valve
2. Delivery note
3. Instruction manual
Step 2
Remove possible packing materials from the valve ports. Avoid
damaging the air connection, the valve ports, the detecting valve
and the CIP valve. Caution!
Remove
packing
materials!
Step 3
Inspect the valve for visible transport damage.
Inspection!
7

3 Installation
3.2 Recycling
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, 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 out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wear parts must be disposed off in agreement with local regulations
•Scrapping
- At end of use, the equipment must be recycled according to the relevant, local regulations. Besides 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
8

3 Installation
The valve sizes DN125-150 are very heavy.
Therefore Alfa Laval recommends manufacturing and usage of auxiliary equipment. A proposal is given below.
Please note that the auxiliary equipment cannot be supplied by Alfa Laval.
The items refers to the drawings, parts list and service kits, see chapter 7 Parts list and service kits
3.3 Recommended auxiliary equipment (DN125/150)
Step 1
For lifting the valve:
Screw an eye bold (6 mm/0.25 inch) into top pin (10). Using a small hook crane or similar, lift the valve by an eye bolt.
Trestle:
- The purpose of the trestle is to support the valve during dismantling and assembly.
- The trestle is made of a base plate, two support plates, two rubber linings and four bolts.
- The rubber linings are attached to the support plates so that the valve/actuator will rest on these.
- To prevent the valve from turning during dismantling and reassembly the trestle must be made with the correct measurements
(see drawings below - all measurements are in mm.)
Trestle Side view
Top view End view
Step 2
1. Place the valve in the trestle.
2. Make sure that the actuator rests on the rubber linings on the
trestle support plates.
3. Dismantle/assemble the valve
TD 430-180
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
CIP = Cleaning In Place
3.4 General installation
Step 1
- Always read the technical data thoroughly (see 6 Technical data).
- Always release compressed air after use.
- Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air.
CAUTION!
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Install the valve so that:
- The actuator is turned to the uppermost point.
- The detecting valve is self-draining.
- The flow is against the closing direction to avoid water hammer.
A=Inlet
Stop valve Change-over valve
A
TD 430-081_1
A
TD 430-093_1
Avoid water hammer!
Step 3
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
Step 4
Fittings:
Ensure that the connections are tight.
Remember seal rings!
10

3 Installation
Study the instructions carefully and pay special attention to the warnings.
The valve has welding ends as standard.
Weld carefully.
Check the valve for smooth operation after welding.
Step 5
Air connection:R1/8”(BSP)
(additional air supply)
Air
R1/8”(BSP)
Step 6
CIP connection:
1. See description of cleaning and optional extras see sections
4.3 Recommended cleaning and 4.4 Cleaning equipment
(optional extra)
2. Connect CIP correctly.
A=CIPin
B = R3/8” (BSP), external thread
C=CIPout/leakagedrain
A
B
C
TD 430-085_1
3.5 Welding
Step 1
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Cutting danger!
1
11

3 Installation
Study the instructions carefully and pay special attention to the warnings.
The valve has welding ends as standard.
Weld carefully.
Check the valve for smooth operation after welding.
Step 2
Dismantle the valve in accordance with steps 1-3, section 5.2
Dismantling of valve
Pay special attention to the warnings!
Step 3
NOTE!
Always weld the valve body into the pipelines so that the valve
body seal rings can be replaced (change-over valve).
Maintain the minimum clearances (A and B) so that the lower valve
plug (change-over valve) and the actuator with the internal parts
can be removed.
AB
1B2
(Incl. top unit)
Valve size
mm (figures in ( ) = inches)
DN40/38mm 280 (11) 550 (22) 730 (29)
DN50/51 mm 305 (12) 550 (22) 730 (29)
DN65/63.5mm 360 (14) 550 (22) 730 (29)
DN80/76mm 410 (16) 600 (24) 780 (31)
DN100/101.6mm 470 (19) 650 (26) 830 (33)
DN125 - (-) 750 (30) 930 (37)
DN150 - (-) 790 (31) 970 (38)
Stop valve Change-over valve
(upper valve body)
B1/B2
TD 430-086_1
1
TD 430-094_1
B1/B2
A
1
1=CAUTI
ON!
Step 4
Assemble the valve in accordance with steps 4-6, section 5.3
Assembly of valve
Pay special attention to the warnings!
12

3 Installation
Study the instructions carefully and pay special attention to the warnings.
The valve has welding ends as standard.
Weld carefully.
Check the valve for smooth operation after welding.
Step 5
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings! Air
Open/close!
13

4Operation
The valve is adjusted and tested before delivery.
Study the instructions carefully and pay special attention to the warnings! Pay attention to possible faults.
CIP = Cleaning In Place
The items refer to the drawing and parts liste, see section 7 Parts list and service kits.
4.1 Operation
Step 1
Always read the technical data thoroughly (see chapter 6 Technical
data ).
Always release compressed air after use.
Never touch the clip assembly or the actuator piston
rod when the actuator is supplied with compressed
air.
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 sterilizing.
Burning danger!
4.2 Fault finding
NOTE! Study the maintenance instructions carefully before replacing worn parts - see section 5.1 General maintenance
Problem Cause/result Possible solution
Product leakage
through the detecting valve
(closed valve)
- Worn seal rings
- The two seal rings affected by
different products
- Incorrect fitting of seal rings
- Product deposits on the seat
and/or plug
- Replace the seal rings
- Select a different rubber grade
- Frequent cleaning
Product leakage
through the detecting valve
(open valve)
- Worn O-ring (26a)
- Worn spindle (26d)
- Product deposits on the seat
and/or plug
- Replace the O-ring
- Replace the spindle
- Frequent cleaning
Product leakage
at stem and/or clamp
- Worn/product affected lip seal (22a)
and/or seal rings (22c, 27) - Replace the seal rings
- Select a different rubber grade
Product leakage
through middle or lower valve body
(closed lower plug)
- Worn/product affected plug seal ring
- Loose parts (vibrations)
- Product deposits on the seat
and/or plug
- Replace the seal ring
- Select a different rubber grade
-Tightenthelooseparts
- Frequent cleaning
- Air leakage through the CIP and
detecting valve
- Air leakage at the actuator
Worn seal rings Replace the seal rings
14

4Operation
The valve is designed for cleaning in place (CIP)
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustric 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 sterilizing.
Burning danger!
Step 3
Always keep the cleaning pressure lower than the product
pressure.
Never throttle the outlet of the detecting valve (risk of mixing
because of overpressure).
1=CIPin
2=CIPvalve
3 = Detecting valve
4=CIPout
Leakage chamber: 60-100 kPa
15

4Operation
The valve is designed for cleaning in place (CIP)
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustric soda
HNO3= Nitric acid
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC (158oF) 2. 0.5% by weight HNO3at 70oC(158
oF)
1kg
(2.2 lbs)
NaOH
+
100 l
(26.4 gal)
water
=Cleaning agent. 0.7 l
(0.2 gal)
53% HNO3
+
100 l
(26.4 gal)
water
=Cleaning agent.
2.2 l
(0.6 gal)
33% NaOH
+
100 l
(26.4 gal)
water
= Cleaning agent.
Step 5
Recommended cleaning periods:
Cleaning periods of 10-15 seconds for the leakage chamber.
Product Periods
Milk 1-2
Yoghurt 3-5
Beer 2-5
Cold wort 5-10
Recommended cleaning flow rates:
(For special processes, see Step 6 ).
Leakage chamber: 12-15 l/min (3.2 - 4.0 gpm).
Step 6
1. Avoid excessive concentration of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the process
Milk sterilization/viscous liquids
⇒Increase the cleaning flow!
Step 7
Internal leakage in the valve is externally visible by means of the
outlet of the detecting valve.
Always rinse well with clean water after the cleaning.
NOTE!
The cleaning agents must be stored/disposed of in accordance
with current rules/directives.
Always rinse!
Clean water Cleaning agents
Step 8
Cleaning cycle:
Pay special attention to the warnings!
Closed stop valve:
Cleaning of the leakage chamber
A=Product
B=CIPin
C=CIPout
A
BC
TD 430-045_1
16

4Operation
The valve is designed for cleaning in place (CIP)
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustric soda
HNO3= Nitric acid
Step 9
Open stop valve:
Cleaning of the valve body and the leakage chamber
A=CIP
A
TD 430-044_1
Step 10
Closed change-over valve:
Cleaning of the upper valve body
A=CIP
B=Product
A
B
TD 430-047_1
17

4Operation
The installation kits are for cleaning of the leakage chamber when the valve is closed.
The combination of the different kits depends on the actual applications.
CIP = Cleaning In Place
4.4 Cleaning equipment (optional extra)
Step 1
Installation kit A for CIP and leakage connections of a single valve (PVDF/stainless steel tubes)
Contents:
Pos. 1-Weldingmalepart
Pos. 2 - Fitting PVDF female
Pos. 3 - Tube PVDF
Pos. 4 - Leakage tube AISI 316
TD 430-158_1
Step 2
Installation kit B (inlet) for parallel connection of CIP (PVDF
tubes)
Contents:
Pos. 2 - Fitting PVDF female
Pos. 3 - Tube PVDF
Pos. 5 - Fitting PVDF
TD 430-157_1
18

4Operation
The installation kits are for cleaning of the leakage chamber when the valve is closed.
The combination of the different kits depends on the actual applications.
CIP = Cleaning In Place
Step 3
Installation kit C for CIP and leakage connection of a single
valve (stainless steel tubes)
Contents:
Pos. 1 - Welding part
Pos. 4 - CIP leakage tube AISI 316
* Adjust and weld during installation.
TD 430-159_1
Step 4
Installation kit D for leakage connection (stainless steel tubes)
Contents:
Pos. 4 - Leakage tube AISI 316
TD 430-160_1
19

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
CIP = Cleaning In Place.
Always keep spare rubber seals, lip seals and guide rings in stock.
5.1 General maintenance
Step 1
-Always read the technical data thoroughly (see 6 Technical
data).
-Always release compressed air after use.
-Always remove the CIP connections before service.
CAUTION!
All scrap must be stored/disposed of in accordance
with current rules/directives.
Step 2
-Never service the valve when it is hot.
-Never service the valve with valve and pipelines under pressure. Atmospheric pressure
required!
Burning danger!
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air!
Cutting danger!
1
Step 4
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air. Moving parts!
Air
20