Alfalaval SMP-BC User manual

ESE02255-EN102022-10
Originalmanual
InstructionManual
SMP-BCSanitaryMixproofValve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetyprecautions................................................................................
3.Installation....................................................................................8
3.1.Unpacking/delivery...............................................................................8
3.2.Recycling..........................................................................................9
3.3.Recommendedauxiliaryequipment(DN125/150).............................................10
3.4.Generalinstallation................................................................................11
3.5.Welding............................................................................................13
4.Operation.....................................................................................15
4.1.Operation..........................................................................................15
4.2.Faultfinding.......................................................................................15
4.3.Recommendedcleaning.........................................................................1
4.4.Cleaningequipment(optionalextra)............................................................20
5.Maintenance..................................................................................22
5.1.Generalmaintenance.............................................................................22
5.2.Dismantlingofvalve..............................................................................24
5.3.Assemblyofvalve.................................................................................26
5.4.Dismantlingofactuator...........................................................................2
5.5.Assemblyofactuator.............................................................................29
5.6.Replacementofplugseals.......................................................................31
6.Technicaldata................................................................................35
6.1.Technicaldata.....................................................................................35
7.Partslistandservicekits...................................................................36
.1.Drawings...........................................................................................36
.2.SMP-BCstopvalve...............................................................................38
.3.SMP-BCchange-overvalve.....................................................................40
.4.SMP-BCstopvalve-sizeDN125/DN150.....................................................44
.5.Toolsforplugseals...............................................................................46
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
SanitaryMixproofValve
Designation
SMP-BCPN10
Type
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-ThevalveisincompliancewiththePressureEquipmentDirective2014/68/ECandwassubjectedtothefollowing
assessmentprocedureModuleA.Diameters≥DN125maynotbeusedforfluidsgroup1.
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2016-06-01
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
SanitaryMixproofValve
Designation
SMP-BCPN10
Type
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations2008
-ThePressureEquipment(Safety)Regulations2016category1andsubjectedtoassessmentprocedureModuleA.
Diameters≥DN125maynotbeusedforfluidsgroup1
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
Allwarningsinthemanualaresummarizedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
2.1Importantinformation
Important Important
Importantinformation information information
Always Always
Alwaysr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the thevalve! valve! valve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures.
2.2Warningsigns
Generalwarning:Causticagents:Cuttingdanger:
6

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
Allwarningsinthemanualaresummarizedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Always Always
Alwaysreleasecompressedairafteruse
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair
Never Never
Neverstickyourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Operation: Operation:
Operation:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Always Always
Alwaysreleasecompressedairafteruse
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodwhentheactuatorissuppliedwithcompressedair
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilizing
Always Always
Alwayskeepthecleaningpressurelowerthantheproductpressure
Never Never
Neverthrottletheoutletofthedetectingvalve
Always Always
Alwayshandlelyeandacidwithgreatcare
Maintenance: Maintenance:
Maintenance:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Always Always
Alwaysreleasecompressedairafteruse
Always Always
AlwaysremovetheCIPconnectionsbeforeservice
Never Never
Neverservicethevalvewhenitishot
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure
Never Never
Neverstickyourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair
T T
Transportation: ransportation: ransportation:
Always Always
Alwaysensurethatcompressedairarereleased
Always Always
Alwaysensurethatallconnectionsisdisconnectedbeforeattemptingtoremovethevalvefromtheinstallation
Always Always
Alwaysdrainliquidoutofvalvesbeforetransportation
Always Always
Alwaysusepredesignedliftingpointsifdefined
Always Always
Alwaysensuresufficientfixingofthevalveduringtransportation-ifspeciallydesignedpackagingmaterialisavailable,it
mustbeused
7

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
StopvalveWithonevalvebody.Change-overvalveWiththreevalvebodies.
CIP=CleaningInPlace
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION! CAUTION!
CAUTION!
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
Check Check
Checkthe the thedelivery delivery deliveryfor: for: for:
1.Completevalve,standardorthree-bodiedvalve
2.Deliverynote
3.Instructionmanual
Step Step
Step2 2 2
Removepossiblepackingmaterialsfromthevalveports.Avoid
damagingtheairconnection,thevalveports,thedetectingvalve
andtheCIPvalve.Caution! Caution!
Caution!
Remove Remove
Remove
packing packing
packing
materials! materials!
materials!
Step Step
Step3 3 3
Inspectthevalveforvisibletransportdamage.
Inspection! Inspection!
Inspection!
8

3Installation
3.2Recycling
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbere-used,recycledorusedforenergyrecovery
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialrecycling.
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearingpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialrecycling
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialrecycling
-Oilandallnon-metalwearpartsmustbedisposedoffinagreementwithlocalregulations
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentmustberecycledaccordingtotherelevant,localregulations.Besidestheequipmentitself,any
hazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactyourlocalAlfaLavalsalescompany
9

3Installation
ThevalvesizesDN125-150areveryheavy.
ThereforeAlfaLavalrecommendsmanufacturingandusageofauxiliaryequipment.Aproposalisgivenbelow.
Pleasenotethattheauxiliaryequipmentcannot cannot
cannotbesuppliedbyAlfaLaval.
Theitemsreferstothedrawings,partslistandservicekits,seechapter7Partslistandservicekits
3.3Recommendedauxiliaryequipment(DN125/150)
Step Step
Step1 1 1
For For
Forlifting lifting liftingthe the thevalve valve valve:
Screwaneyebold(6mm/0.25inch)intotoppin(10).Usingasmallhookcraneorsimilar,liftthevalvebyaneyebolt.
T T
Tr r restle estle estle:
-Thepurposeofthetrestleistosupportthevalveduringdismantlingandassembly.
-Thetrestleismadeofabaseplate,twosupportplates,tworubberliningsandfourbolts.
-Therubberliningsareattachedtothesupportplatessothatthevalve/actuatorwillrestonthese.
-Topreventthevalvefromturningduringdismantlingandreassemblythetrestlemustbemadewiththecorrectmeasurements
(seedrawingsbelow-allmeasurementsareinmm.)
T T
Tr r restle estle estleSide Side
Sideview view view
T T
Top op opview view viewEnd End Endview view view
Step Step
Step2 2 2
1.Placethevalveinthetrestle.
2.Makesurethattheactuatorrestsontherubberliningsonthe
trestlesupportplates.
3.Dismantle/assemblethevalve
10

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
CIP=CleaningInPlace
3.4Generalinstallation
Step Step
Step1 1 1
-Alwaysreadthetechnicaldatathoroughly(see6Technicaldata).
-Alwaysreleasecompressedairafteruse.
-Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair.
CAUTION! CAUTION!
CAUTION!
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
Step Step
Step2 2 2
Installthevalvesothat:
-Theactuatoristurnedtotheuppermostpoint.
-Thedetectingvalveisself-draining.
-Theflowisagainsttheclosingdirectiontoavoidwaterhammer.
A=Inlet
Stop Stop
Stopvalve valve valveChange Change Change- - -over over overvalve valve valve
A A
Avoid void voidwater water waterhammer! hammer! hammer!
Step Step
Step3 3 3
Avoidstressingthevalve.
Payspecialattentionto:
-Vibrations.
-Thermalexpansionofthetubes.
-Excessivewelding.
-Overloadingofthepipelines.
Risk Risk
Riskof of ofdamage! damage! damage!
11

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
CIP=CleaningInPlace
Step Step
Step4 4 4
Fittings Fittings
Fittings:
Ensurethattheconnectionsaretight.
Remember Remember
Rememberseal seal sealrings! rings! rings!
Step Step
Step5 5 5
Air Air
Airconnection connection connection:
Ifactuatorissupportedbyaironspringside;
maxallowablepressureis300kPa(3bar)
R1/8”(BSP)
(additionalairsupply)
Air
R1/8”(BSP)
Step Step
Step6 6 6
CIP CIP
CIPconnection connection connection:
1.Seedescriptionofcleaningandoptionalextrasseesections
4.3Recommendedcleaningand4.4Cleaningequipment
(optionalextra)
2.ConnectCIPcorrectly.
A=CIPin
B=R3/8”(BSP),externalthread
C=CIPout/leakagedrain
3.5Welding
12

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings.
Thevalvehasweldingendsasstandard.
Weldcarefully.
Checkthevalveforsmoothoperationafterwelding.
Step Step
Step1 1 1
Never Never
Neverstickyourfingersthroughthevalveportsiftheactuatoris
suppliedwithcompressedair.
Air
Cutting Cutting
Cuttingdanger! danger! danger!
Step Step
Step2 2 2
Dismantlethevalveinaccordancewithsteps1-3,section5.2
Dismantlingofvalve
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Step Step
Step3 3 3
NOTE! NOTE!
NOTE!
Always Always
Alwaysweldthevalvebodyintothepipelinessothatthevalve
bodysealringscanbereplaced(change-overvalve).
Maintaintheminimumclearances(AandB)sothatthelowervalve
plug(change-overvalve)andtheactuatorwiththeinternalparts
canberemoved.
A A
AB B B1 1
1B B
B2 2
2
(Incl. (Incl.
(Incl.top top topunit) unit) unit)
V V
Valve alve alvesize size size
mm mm
mm(figuresin()=inches)
DN40/38mm280(11)550(22)30(29)
DN50/51mm305(12)550(22)30(29)
DN65/63.5mm360(14)550(22)30(29)
DN80/6mm410(16)600(24)80(31)
DN100/101.6mm40(19)650(26)830(33)
DN125-(-)50(30)930(3)
DN150-(-)90(31)90(38)
Stop Stop
Stopvalve valve valveChange Change
Change- - -over over overvalve valve valve
(uppervalvebody)
1 1
1= = =CAUTION! CAUTION! CAUTION!
13

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings.
Thevalvehasweldingendsasstandard.
Weldcarefully.
Checkthevalveforsmoothoperationafterwelding.
Step Step
Step4 4 4
Assemblethevalveinaccordancewithsteps4-6,section5.3
Assemblyofvalve
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Step Step
Step5 5 5
Pr Pr
Pre e e- - -use use usecheck check check:
1.Supplycompressedairtotheactuator.
2.Openandclosethevalveseveraltimestoensurethatit
operatessmoothly.
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!Air
Open/close! Open/close!
Open/close!
14

4Operation
Thevalveisadjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Payattentiontopossiblefaults.
CIP=CleaningInPlace
Theitemsrefertothedrawingandpartsliste,seesection7Partslistandservicekits.
4.1Operation
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technical
data).
Always Always
Alwaysreleasecompressedairafteruse.
Never Never
Nevertouchtheclipassemblyortheactuatorpiston
rodwhentheactuatorissuppliedwithcompressed
air.
CAUTION! CAUTION!
CAUTION!
AlfaLavalcannotbeheldresponsibleforincorrect
operation.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquids
orwhensterilizing.
Bur Bur
Burning ning ningdanger! danger! danger!
4.2Faultnding
NOTE! NOTE!
NOTE!Studythemaintenanceinstructionscarefullybeforereplacingwornparts-seesection5.1Generalmaintenance
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultPossible Possible
Possiblesolution solution solution
Productleakage
throughthedetectingvalve
(closedvalve)
-Wornsealrings
-Thetwosealringsaffectedby
differentproducts
-Incorrectfittingofsealrings
-Productdepositsontheseat
and/orplug
-Replacethesealrings
-Selectadifferentrubbergrade
-Frequentcleaning
Productleakage
throughthedetectingvalve
(openvalve)
-WornO-ring(26a)
-Wornspindle(26d)
-Productdepositsontheseat
and/orplug
-ReplacetheO-ring
-Replacethespindle
-Frequentcleaning
Productleakage
atstemand/orclamp
-Worn/productaffectedlipseal(22a)
and/orsealrings(22c,2)-Replacethesealrings
-Selectadifferentrubbergrade
Productleakage
throughmiddleorlowervalvebody
(closedlowerplug)
-Worn/productaffectedplugsealring
-Looseparts(vibrations)
-Productdepositsontheseat
and/orplug
-Replacethesealring
-Selectadifferentrubbergrade
-Tightenthelooseparts
-Frequentcleaning
15

4Operation
Thevalveisadjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Payattentiontopossiblefaults.
CIP=CleaningInPlace
Theitemsrefertothedrawingandpartsliste,seesection7Partslistandservicekits.
-AirleakagethroughtheCIPand
detectingvalve
-Airleakageattheactuator
WornsealringsReplacethesealrings
16

4Operation
Thevalveisdesignedforcleaninginplace(CIP)
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=Caustricsoda
HNO3=Nitricacid
4.3Recommendedcleaning
Step Step
Step1 1 1
Always Always
Alwayshandlelyeandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Always Always
Alwaysuse
rubbergloves!
Always Always
Alwaysuse
protectivegoggles!
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhensterilizing.
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step3 3 3
Always Always
Alwayskeepthecleaningpressurelowerthantheproduct
pressure.
Never Never
Neverthrottletheoutletofthedetectingvalve(riskofmixing
becauseofoverpressure).
1=CIPin
2=CIPvalve
3=Detectingvalve
4=CIPout
Leakagechamber:60 60
60- - -100 100 100kPa kPa kPa
17

4Operation
Thevalveisdesignedforcleaninginplace(CIP)
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=Caustricsoda
HNO3=Nitricacid
Step Step
Step4 4 4
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents agents agents:
Usecleanwater,freefromchlorides.
1.1%byweightNaOHat0oC(158oF)2.0.5%byweightHNO3at0oC(158oF)
1kg
(2.2lbs)
NaOH
+
100l
(26.4gal)
water
=Cleaningagent.0.l
(0.2gal)
53%HNO3
+
100l
(26.4gal)
water
=Cleaningagent.
2.2l
(0.6gal)
33%NaOH
+
100l
(26.4gal)
water
=Cleaningagent.
Step Step
Step5 5 5
Recommended Recommended
Recommendedcleaning cleaning cleaningperiods: periods: periods:
Cleaningperiodsof10-15secondsfortheleakagechamber.
Pr Pr
Product oduct oductPeriods Periods Periods
Milk1-2
Yoghurt3-5
Beer2-5
Coldwort5-10
Recommended Recommended
Recommendedcleaning cleaning cleaningflow flow flowrates rates rates:
(Forspecialprocesses,seeStep6).
Leakagechamber:12-15l/min(3.2-4.0gpm).
Step Step
Step6 6 6
1.Avoidexcessiveconcentrationofthecleaningagent
⇒Dose Dose
Dosegradually! gradually! gradually!
2.Adjustthecleaningflowtotheprocess
Milk Milk
Milksterilization/viscous sterilization/viscous sterilization/viscousliquids liquids liquids
⇒Incr Incr
Increase ease easethe the thecleaning cleaning cleaningflow! flow! flow!
Step Step
Step
Internalleakageinthevalveisexternallyvisiblebymeansofthe
outletofthedetectingvalve.
Always Always
Alwaysrinsewellwithcleanwaterafterthecleaning.
NOTE! NOTE!
NOTE!
Thecleaningagentsmustbestored/disposedofinaccordance
withcurrentrules/directives.
Always Always
Alwaysrinse! rinse! rinse!
CleanwaterCleaningagents
Step Step
Step8 8 8
Cleaning Cleaning
Cleaningcycle: cycle: cycle:
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Closed Closed
Closedstop stop stopvalve: valve: valve:
Cleaningoftheleakagechamber
A=Product
B=CIPin
C=CIPout
18

4Operation
Thevalveisdesignedforcleaninginplace(CIP)
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=Caustricsoda
HNO3=Nitricacid
Step Step
Step9 9 9
Open Open
Openstop stop stopvalve: valve: valve:
Cleaningofthevalvebodyandtheleakagechamber
A=CIP
Step Step
Step10 10 10
Closed Closed
Closedchange change change- - -over over overvalve valve valve:
Cleaningoftheuppervalvebody
A=CIP
B=Product
19

4Operation
Theinstallationkitsareforcleaningoftheleakagechamberwhenthevalveisclosed.
Thecombinationofthedifferentkitsdependsontheactualapplications.
CIP=CleaningInPlace
4.4Cleaningequipment(optionalextra)
Step Step
Step1 1 1
Installation Installation
Installationkit kit kitA A A(inlet) (inlet) (inlet)for for forparallel parallel parallelconnection connection connectionof of ofCIP CIP CIP(PVDF
tubes)
Contents Contents
Contents:
Pos.2-FittingPVDFfemale
Pos.3-TubePVDF
Pos.5-FittingPVDF
Step Step
Step2 2 2
Installation Installation
Installationkit kit kitB B Bfor for forCIP CIP CIPand and andleakage leakage leakageconnections connections connectionsof of ofa a asingle single singlevalve valve valve(PVDF/stainlesssteeltubes)
Contents Contents
Contents:
Pos.1-Weldingmalepart
Pos.2-FittingPVDFfemale
Pos.3-TubePVDF
Pos.4-LeakagetubeAISI316
20