Alfalaval SRC PN10 User manual

ESE02590-EN3 2016-03
Original manual
Instruction Manual
Unique Single Seat Valve (DN125-150)

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. 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/general installation ......................................................... 7
3.2. Recommended auxiliary equipment ............................................................ 8
3.3. General installation ................................................................................ 9
3.4. Welding ............................................................................................ 11
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Fault finding ....................................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling of valve .............................................................................. 20
5.3. Valve assembly .................................................................................... 22
5.4. Dismantling of actuator ........................................................................... 24
5.5. Assembly of actuator ............................................................................. 25
6. Technical data ......................................................................................... 26
6.1. Technical data ..................................................................................... 26
7. Drawings ................................................................................................ 27
7.1. Drawings ........................................................................................... 27
8. Parts list and service kits ............................................................................ 28
8.1. Shut-off valve ...................................................................................... 28
8.2. Change-over valve ................................................................................ 30
3

1 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
Valve
Designation
SRC 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 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.
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:
5

2 Safety
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 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.
Transportation:
Always secure that compressed air is released
Always secure that all connections is disconnected before attemt to remove the valve from the installation
Always drain liquid out of valves before transportation
Always used 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
6

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery/general installation
Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery:
1. Complete valve, shut-off valve or change-over valve (see step 2 and 3)
2. Delivery note
3. Instruction Manual
Step 2
Shut-off valve:
1. Complete actuator with bonnet (8)
2. Clip assembly (11)
3. Lip seal (14)
4. Clamp (15)
5. Valve plug (19)
6. Valve body (16)
TD425-039_1
Step 3
Change-over valve:
1. Complete actuator with bonnet (8)
2. Clip assembly (11)
3. Lip seal (14)
4. Two clamps (15)
5. Valve plug (20)
6. Two valve bodies (16, 18)
7. Valve body seal ring (17) TD425-060_1
Step 4
- Remove possible packing materials from the valve/valve parts
- Inspect the valve/valve parts for visible transport damages
- Avoid damaging the valve/valve parts
Inspection!
Remove packing materials!
TD425-040_1
7

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 refer to the parts list and service kits section.
3.2 Recommended auxiliary equipment
Step 1
For lifting the valve
Screw an eye bolt (6 mm) (1/4”) into top pin (23). Using a small
hook crane or similar, lift the valve by the eye bolt.
Trestle:
- The purpose of the trestle is to support the valve during dismantling and reassembly.
- 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 assembly the trestle must be made with the correct measurements
(see below). All measurements are in mm.
TD425-159_1
10mm(0.4”)
50mm(2”)
50mm(2”)
TD425-160_1
Trestle Side view
TD425-161_1
250mm(9.8”)
250mm(9.8”)
101.5mm(4”)
R99.5mm(3.9”)
TD425-162_1
Top view En d 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.
TD425-163_1
8

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.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
3.3 General installation
Step 1
Always read the technical data thoroughly.
See chapter 6 Technical data
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air (see the warning label).
Air
Moving parts!
Air
Step 3
It is recommended to install the valve so that:
- The actuator is not turned downwards as the valve will then
not be drained.
- The flow is against the closing direction to avoid water
hammering
Shut-off valve Change-over valve
Avoid water
hammer! Inlet
Inlet Inlet
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.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes
- Excessive welding
- Overloading of the pipelines Risk of
damage!
Step 5
Fittings:
Ensure that the connections are tight.
Remember seal
rings!
Step 6
Air connection: Air R1/8”(BSP) Air
Air
NO NC A/A
10

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section. Check the valve for smooth operation after welding.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
3.4 Welding
Step 1
Always weld the valve so that the valve body seal ring can be replaced (change-over valve). Maintain the minimum clearances (A
and B) so that the lower valve body and plug (change-over valve) and the actuator with the internal parts can be removed.
Valve size A(mm)(inch) B
1(mm) (inch) B2(mm) (inch)
DN125 580 (22.8) 730 (28.7) 920 (36.2)
DN150 640 (25.1) 730 (28.7) 920 (36.2)
Shut-off valve Change-over valve
(upper valve body)
TD425-044_2
B1/ B2
TD425-061_2
B1/ B2A
Step 2
Shut-off valve
Assemble the valve in accordance with steps 1-5 in section 4.3
Recommended cleaning
Pay special attention to the warnings!
Fit seal ring (17) correctly!
TD425-045_1
Step 3
Change-over valve
Assemble the valve in accordance with step 1-6 in section 4.3
Recommended cleaning
Pay special attention to the warnings!
Fit seal ring (17) correctly!
TD425-062_1
Remember seal rings!
11

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section. Check the valve for smooth operation after welding.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
Step 4
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 (NO/AA)
Open/close!
TD425-046_1
Air (NC/AA)
12

4Operation
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.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
4.1 Operation
Step 1
- Always read the technical data thoroughly (see chapter 6 Technical data)
- Always release compressed air after use.
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.
Burn hazard!
Step 3
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air.
Air (NO)
Moving parts!
Air (NC/AA)
Step 4
Lubrication of valve:
1. Ensure smooth movement between lip seal (14) and plug stem
(19, 20).
2. Lubricate the lip seal with silicone oil/grease if necessary.
Shut-off valve Change-over valve
Lubricate if necessary!
(see section 5.1 General maintenance)
13

4Operation
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.
NO = Normally open. NC = Normally closed. A/A = Air/air activated.
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate all seals with oil/grease if necessary. Lubricate if necessary!
(see section 5.1 General
maintenance)
14

4Operation
Pay attention to possible faults.
Study the instructions carefully.
The items refer to the parts list and service kits section
4.2 Fault finding
Problem Cause/result Repair
The valve plug jerks The lealings seize Lubricate:
-O-rings(2)
- O-ring (5) and the inside of cylinder (3)
- Lip seal (14)
Product leakage
at stem and/or clamp
- Worn/product affected lip seal (14) and/or
seal ring (17) - Replace the seal
- Replace with a seal of a
different rubber grade
Product leakage
(closed valve)
- Worn/product affected
- Loose plug parts (vibrations)
- Product deposits on the seat and/or plug
- Replace the seal ring
- Replace with a seal of a different rubber
grade
-Tightenthelooseparts
- Frequent cleaning
Product leakage
(too high pressure or too
small actuator)
- Worn actuator O-rings
- Too small actuator or actuator spring - Replace the O-rings - Replace with a larger actuator
(for valve sizes DN/OD38-63.5 mm/
DN40-65)
- Fit a stronger spring (for valve sizes
DN/OD38-63.5 mm/DN40-65)
- Use auxiliary air on the spring
side (NOT-element)
Water hammer The flow direction is the same as the closing
direction
- The flow direction should be against the
closing direction
- Fit a damper on the valve (optional extra)
- Use auxiliary air on the spring side
(NOT-element)
The valve does not open/close - Faulty clip assembly (11)
- The pressure on the plug plug is too high - Replace the clip assembly
- Reduce the pressure plug is too high
- Fit stronger spring/larger actuator (for
valve sizes DN/OD38-63.5 mm/ DN40-65)
15

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.
Burn hazard!
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily!
Shut-off valve Change-over valve
Open!
Step 4
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70o(158oF). 2. 0.5% by weight HNO3at 70oC
1kg
(2.2 lb)
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.
16

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
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. Always rinse well with clean water after the cleaning.
Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance with current regulations/directives.
17

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
5.1 General maintenance
Step 1
Always read the technical data thoroughly.
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.
Never service the valve with valve and pipelines under pressure.
Atmospheric
pressure
required!
Burn
hazard!
Step 3
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.
Air
Cutting
hazard!
Moving
parts! Air
TD425-041_1
18

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
Product rubber seals Valve lip seal Actuator rubber seals
Preventive maintenance
Replace after
12 months depending
on working conditions
Replace when replacing the
rubber seals
Replace after
5 years
Maintenance after
leakage (leakage
normally starts slowly)
Replace at the
end of the day Replace when replacing the
rubber seals
Replace when
possible
Planned
maintenance
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
planning of inspections
Replace after leakage
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
planning of inspections
Replace after leakage
Lubrication
(USDA H1
approved oil/grease)
Before fitting
Silicone oil or
silicone grease
Before fitting
Silicone oil or silicone grease
Before fitting
Oil or grease
Pre-use check: Air (NO/AA)
Open/close! Air (NC/AA)
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!
TD425-046_1
Ordering spare parts
Recommended spare: Service kits (see chapter 6 Technical data).
19

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.
NC = Normally closed. NO = Normally open. A/A = Air/air activated.
5.2 Dismantling of valve
Step 1
Change-over valve:
1. Supply compressed air to the actuator (only NC)
2. Loosen and remove lower clamp (15)
3. Release compressed air (18)
4. Pull out seal ring (17)
5. Release compressed air
Pay special attention to the warnings!
Air (NC/A/A)
TD425-069_1
Step 2
Shut-off valve:
1. Supply compressed air to the actuator (only NC)
2. Loosen and remove clamp (15)
3. Lift out the actuator
4. Release compressed air
Pay special attention to the warnings! Air (NC/A/A)
TD425-056_1
Step 3
Shut-off valve:
1. Supply compressed air to the actuator (only NC)
2. Remove clip assembly (11) by using plugs
(For sizes Dn125-150: Unscrew valve plug(19,20))
3. Remove valve plug (19,20)
4. Release compressed air
Pay special attention to the warnings!
Air (NO) Air (NC/A/A)
TD425-070_1
Shut-off valve Change-over valve
Step 4
Change-over valve:
1. Remove upper clamp (15)
2. Remove upper valve body (16)
TD425-071_1
20