Alfalaval SMP-BCA User manual

TD 440-072_1
TD 440-073
ESE02251-EN3 2016-06
Original manual
Instruction Manual
SMP-BCA Aseptic Mixproof Valve with PTFE Diaphragm
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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 information ............................................................................. 8
3.3. General installation ................................................................................ 8
3.4. Welding ............................................................................................ 11
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Fault finding ....................................................................................... 13
4.3. Recommended cleaning ......................................................................... 14
4.4. Cleaning and sterilization equipment (optional extra) .......................................... 16
5. Maintenance ........................................................................................... 17
5.1. General maintenance ............................................................................. 17
5.2. Dismantling of valve .............................................................................. 19
5.3. Assembly of valve ................................................................................. 20
5.4. Dismantling of actuator ........................................................................... 23
5.5. Assembly of actuator ............................................................................. 24
5.6. Replacement of plug seals ....................................................................... 25
6. Technical data ......................................................................................... 29
6.1. Technical data ..................................................................................... 29
7. Parts list and service kits ............................................................................ 31
7.1. Stop valve ......................................................................................... 34
7.2. Change-over valve ................................................................................ 38
7.3. Tool for plug seals ................................................................................ 42
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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
- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A.
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 2016-06-15
Place Date Signature
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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.
2.1 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: Cutting danger:
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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 6.1 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 6.1 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 handle lye and acid with great care.
Always keep the cleaning pressure lower than the product pressure.
Never throttle the outlet of the detecting valve.
Maintenance:
Always read the technical data thoroughly (see chapter 6.1 Technical data). !
Always release compressed air after use.
Always remove the CIP connections before service.
Never service the valve when it is hot.
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 used 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.
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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 (see 4.3 Recommended cleaning).
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 and the valve ports, the detecting
valveandtheCIPvalve. Caution!
Remove packing
materials!
Step 3
Inspect the valve for visible transport damage.
Inspection!
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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 (see section 4.3 Recommended cleaning).
3.2 Recycling information
• 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.
3.3 General installation
Step 1
- Always read the technical data thoroughly (see 6.1 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.
Stop valve Change-over valve
Inlet
Inlet
Avoid water hammer!
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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 (see section 4.3 Recommended cleaning).
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!
Step 5
Drain connection:
The drain hose on the bonnet should always be connected to a
tube so that no personal injury can occur in case of a leakage.
Air connection
R1/8”(BSP) R1/8”(BSP)
(additional air supply)
Air - R1/8”(BSP)
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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 (see section 4.3 Recommended cleaning).
Step 6
CIP/Steam connection:
1. See the description of cleaning and optional extras in section
4.3 Recommended cleaning.
2. Connect CIP correctly.
3. Internal steam pressure must not exceed 120°C/200 kPa (2
bar).
A = CIP/Steam in
B = R3/8” (BSP), external thread
C = CIP/Steam out or leakage drain
A
B
C
TD 440-009_1
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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.
3.4 Welding
Step 1
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air!
Cutting danger!
Step 2
Dismantle the valve in accordance with Step 1- Step 3 in 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.
AB1
B2 (incl. top
unit)
Valve size
mm/inch
DN40/38 mm 280/11 580/22.8 760/30
DN50/51 mm 305/12 580/22.8 760/30
DN65/63.5 mm 360/14 580/22.8 760/30
DN80/76 mm 410/16 630/24.8 810/31.9
DN100/101.6 mm 470/19 630/24.8 860/33.9
Stop valve Change-over valve
(upper valve body)
B1 / B2
TD 440-010_1
B1 / B2
A
TD 440-003_1
Step 4
Assemble the valve in accordance with Step 4 - Step 9 in section 5.3 Assembly of valve.
Pay special attention to the warnings!
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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 a few times to ensure that it operates
smoothly.
Pay special attention to the warnings! Open/close! Air
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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.
The items refer to the drawings and parts - see section 7 Parts list and service kits
CIP = Cleaning In Place (see section 4.3 Recommended cleaning).
4.1 Operation
Step 1
- Always read the technical data thoroughly (see 6.1 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 drain tube and/or
clamp
Worn/product affected diaphragm set
(22) and/or seal rings (17)
- Replace the seal rings or diaphragm
set
- 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
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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!
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).
Sterile barrier chamber:
Max. CIP press. 60-100 kPa (0.6-1 bar)
Max. steam press. 200 kPa (2 bar)/120oC
A = CIP/steam in C = Detecting valve
B=CIP/
steam valve D=CIPo ut
TD 440-012_1
A
BCD
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC 2. 0.5% by weight HNO3at 70oC
1kgNaOH + 100 l water = Cleaning agent. 0.7 l
53% HNO3+100 l water =Cleaning
agent.
2.2 l
33% NaOH +100 l
water = Cleaning agent.
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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.
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
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!
Step 9
Closed Stop valve:
Cleaning of sterile barrier chamber
A=Product
B = CIP/steam in
C = CIP/steam out A
B
TD 440-016_1
C
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4Operation
The installations kits are for cleaning/sterilizing of the leakage chamber when the valve is closed.
The stainless steel tubes must be cut and welded during installation.
CIP = Cleaning In Place.
Step 10
Open Stop valve:
Cleaning of the valve body and the leakage chamber
A=CIP
A
TD 440-014_1
Step 11
Change-over valve:
Cleaning of the upper valve body
A=CIP
B=Product
A
B
TD 440-018_1
4.4 Cleaning and sterilization equipment (optional extra)
Step 1
Installation kit C for CIP/steam and leakage connection of a single
valve (stainless steel tubes).
Contents:
Pos. 1 Welding male part
Pos. 4 CIP leakage tube AISI 316
* Adjust and weld during installation.
TD 440-071_1
Step 2
To ensure aseptic processing and mixproof function certain rules must be followed:
- After the valve is closed the leakage chamber must be cleaned and sterilized.
- The leakage chamber must be kept sterile until the valve is opened again.
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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 6.1 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!
Step 4
Never touch the clip assemblyortheactuatorpistonrodifthe
actuator is supplied with compressed air. Moving parts!
Air
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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.
The valve is designed so that single internal leakages do not resolve in the products becoming mixed.
Internal leakage in the valve is externally visible.
Check the valve for smooth operation after service.
Ordering spare parts
- Contact the Sales Department.
- Order from the Spare Parts List.
Recommended spare parts: Service kits (see Spare Parts List - see section 7 Parts list and service kits).
Valve diaphragm unit Valve rubber seals Actuator rubber seals Bonnet guide ring
and O-rings
Preventive maintenance Replace after 12
months (depending
on working conditions)
Replace when replacing
the diaphragms
Replace after 5 years Replace when replacing
the actuator rubber seals
(*)
Maintenance after
leakage (leakage
normally starts slowly)
Replace by the end of
the day
Replace when replacing
the diaphragms
Replace when possible Replace when replacing
the actuator rubber seals
(*)
Planned maintenance - Regular inspection
for leakage and
smooth operation
- Keep a record of the
valve
- Use the statistics
for planning of
inspections
Replace after leakage
Replace when replacing
the diaphragms
- Regular inspection
for leakage and
smooth operation
- Keep a record of the
actuator
- Use the statistics
for planning of
inspections
Replace after air
leakage
Lubrication (USDAH1
approved oil/grease)
Before fitting
Silicone oil or silicone
grease
Before fitting
Silicone oil or silicone
grease
Before fitting
Silicone oil or silicone
grease
Lubricate O-rings before
fitting. Silicone oil or
silicone grease
(*) IMPORTANT!
Check that the guide ring is fitted if replacing the bonnet.
Water: 3-4 bar
Inspection
Pre-use check:
1. Ensure that the valve plug seals against the
seat.
Pay special attention to the warnings!
2. Pressurise the sterile barrier chamber by
means of water.
3. Check that the plug seals are tight (no water
leakage through the valve ports).
4. Supply compressed air to the actuator
5. Open and close the valve a few times to ensure
that it operates smoothly.
Pay special attention to the warnings! 1=In
2=Out
3=CIPvalve
4 = Detecting valve
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5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in chapter 7 Parts list and service kits.
Lubricate the rubber seals and the diaphragms before fitting them.
5.2 Dismantling of valve
Step 1
1. Loosen and remove lower clamp (19).
2. Take away lower valve body (31).
3. Pull out seal ring (17).
Change-over valve
Step 2
1. Unscrew lower plug (30).
2. Pull off seal ring (30a) (see special instruction in section 5.6
Replacement of plug seals).
3. Loosen and remove upper clamp (19).
4. Take away middle valve body (27).
5. Pull off O-ring (28) and seal ring (17).
Change-over valve
Step 3
1. Loosen and remove lower diaphragm clamp(19).
2. Take away upper valve body (25).
Change-over valve Stop valve
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5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in chapter 7 Parts list and service kits.
Lubricate the rubber seals and the diaphragms before fitting them.
Step 4
1. Remove clip assembly (9).
2. Remove upper plug with complete diaphragm/stem unit.
3. Remove washer (20) (stop valves only).
4. Loosen and remove upper diaphragm clamp (19).
5. Take away intermediate piece (18).
6. Remove seal ring (17) from the intermediate piece.
Change-over valve Stop valve
Step 5
1. In sequence, turn lower and upper stem (29,21) anticlockwise
(for stop valve: only upper stem) to separate them from upper
plug (24) (counterhold with a spanner).
2. Remove diaphragms (22a, 22b), L-seal (22c) and stem seal
(22d) from the upper plug.
3. Remove diaphragm ring (23) and seal ring (17) from upper valve
plug (25) (only for valve sizes 76-101.6mm/ DN80-100).
Step 6
1. Remove air fitting (26g).
2. Unscrew CIP valve housing (26f).
3. Pull out CIP valve plug (26d).
4. Remove CIP valve spring (26b).
5.3 Assembly of valve
Step 1
1. Fit CIP valve spring (26b) on CIP valve plug (26d).
2. Insert the CIP valve plug with spring in the CIP valve body.
3. Screw CIP valve housing (26f) onto the CIP valve body.
4. Screw air fitting (26g) into the CIP valve housing.
Step 2
Fit seal rings (24b, 24c) and seal ring (30a) on plugs (see special
instructions in section 5.6 Replacement of plug seals).
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