Alfalaval UltraPure Series User manual

2508-0051
ESE02132-EN2 2013-09
Original manual
Instruction Manual
Radial Diaphragm Valve UltraPure

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. CE 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. General installation ................................................................................ 8
3.3. Welding ............................................................................................ 10
3.4. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation .......................................................................................... 12
4.2. Troubleshooting ................................................................................... 13
4.3. Recommended cleaning ......................................................................... 15
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling the valve ............................................................................. 20
5.3. Diaphragm replacement .......................................................................... 21
5.4. Assembly of valve ................................................................................. 23
5.5. Disassembly of actuator ......................................................................... 24
5.6. Assembly of actuator ............................................................................. 27
6. Technical data ........................................................................................ 28
6.1. Technical data ..................................................................................... 28
7. Parts list and service kits ............................................................................ 30
7.1. Radial Diaphragm Valve UltraPure - shut off - actuator ....................................... 30
7.2. Radial Diaphragm Valve UltraPure - shut off - manual ........................................ 32
7.3. Radial Diaphragm Valve UltraPure - tank outlet - actuator ................................... 34
7.4. Radial Diaphragm Valve UltraPure - tank outlet - manual ..................................... 36
3

1 CE Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Radial Diaphragm Valve UltraPure Diaphragm Valves November 2011
Denomination Type Year
is in conformity with the following directives:
-Mac
hinery Directive 2006/42/EC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.
Note: Tank outlet valve is not prepared for build into pressure vessels according to PED/ASME, but only into “open” vessels.
Manager, Product Centres, Compact
Heat Exchangers & Fluid Handling
Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised 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 summarised 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 moving parts if the actuator is supplied with compressed air.
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never dismantle the valve with the valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Operation:
Never dismantle the valve with the valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always read the technical data thoroughly. (See chapter 6 Technical data)
Always release compressed air after use.
Never touch the valve or pipelines when processing hot liquids or when sterilising.
Never touch the moving parts if the actuator is supplied with compressed air.
Always rinse well with clean water after cleaning.
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.
Never service the valve when it is hot.
Never service the valve with the valve and pipelines under pressure.
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.
Transportation:
Always secure that compressed air is released.
Always secure that all connections are disconnected before attempting to remove the valve from the installation.
Always drain liquid out of valves before transportation.
Always use pre-designed lifting points if defined.
Always secure 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.
The items refer to Parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve, tank outlet, manual shut off or
manual tank outlet valve (see steps 2 and 3)
2. Delivery note
3. Instruction Manual
4. Q doc Manual
Step 2
Shut-off valve and tank outlet valve
1. Complete actuator
2. Diaphragm
3. Clamp (wingnut or hexnut)
4. Valve body
1
2
4
3
2508-0052
Step 3
Manual shut-off valve and tank outlet valve
1. Manual actuator
2. Diaphragm
3. Clamp (wingnut or hexnut)
4. Lower valve body
1
2
4
3
2508-0053
Step 4
Remove any possible packing materials from the valve/valve parts
Step 5
Inspect the valve and valve parts for visible transport damages.
Avoid damaging the valve and valve parts.
Check that the Q-doc. serial number and the “Q-doc manual
number” are identical.
2508-0054
Q-doc serial number
7

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends and a clamp fitting on the bottom as standard but can also be supplied with clamp fittings on
the port ends.
3.2 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 moving parts if the actuator is supplied with
compressed air.
Moving
parts!
2508-0055
Moving parts!
Step 3
Avoid putting stress on the valve.
Pay special attention to:
-Vibrations
- Thermal expansion of the pipelines
- Excessive welding
- Overloading of the pipelines
2508-0056
Risk of damage!
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends and a clamp fitting on the bottom as standard but can also be supplied with clamp fittings on
the port ends.
Step 4
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammer.
Outlet
2508-0062_1
Inlet
Step 5
It is recommended that the leakage hole in the pneumatic/manual
actuator is placed so it is visible.
If there is fluid sleeping from the leakage hole the diaphragm is
worn out and must be replaced.
2508-0063_1
Leakage hole
9

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding. The items refer to the Parts list and service kits section.
Check the valve for smooth operation after welding. Man = Manually open and close, NC = Normally closed.
3.3 Welding
Step 1
Always weld the valve so that the actuator with the internal parts
can be removed.
Valve size
DN/OD
Amm(inch)
Air actuator
Bmm(inch)
Manual actuator
12.7 mm (½ inch) 132 mm (5.2 inch) 92 mm (3.6 inch)
25 mm (1 inch) 168 mm (6.6 inch) 98 mm (3.9 inch)
38 mm (1½ inch) 182 mm (7.1 inch) 112 mm (4.4 inch)
NOTE! If there is a risk of foot damage, Alfa Laval recommends to
leave a distance of 120 mm (4.7”) below the actuator.
2508-0057
A
B
Step 2
Placement of the tank outlet valve
The valve housing is usually placed according to the figure
below, but other locations may exist
2508-0058
øC
A
e.g. Weldplate mixer
A = Min. distance between the weld in components, in
accordance with the PED.
Diameter of weld flange (hole)
Valve size øC
12.7 mm / ½ inch ø50 mm / 1.97 inch
25 mm / 1 inch ø79 mm / 3.11 inch
38 mm / 1½ inch ø85 mm / 3.35 inch
A hole (see table) for the valve is cut in the tank plate.
Grind the edge so there is no gap between valve and tank plate.
Only use pulsed arc welding (low heat input) to avoid deforming the valve body.
Tack weld always on the opposite side (8 segments with filler metal).
Weld root if possible without filler metal.
Welding of the final run must be done in 8 segments to avoid cracking.
The inside and outside of the weld is ground and polished to the required finish.
TD 449-244
4
8
51
26
7
3
10

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding. The items refer to the Parts list and service kits section.
Check the valve for smooth operation after welding. Man = Manually open and close, NC = Normally closed.
Step 3
Shut off and tank outlet valves:
Assemble the valve is accordance with the steps in section 5.4
Assembly of valve .
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!
Moving parts!
2508-0060
Moving parts!
3.4 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 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 wearing parts must be taken care of in accordance with local regulations.
• Scrapping
- At the end of use, the equipment should be recycled according to relevant, local regulations. Apart from 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 the local Alfa Laval sales company.
11

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.
A-A = Air open and close, NC = Normally closed.
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 pipelines when processing hot liquids
or when sterilising.
The manually handle will get hot - use hand protection if the valve
must be operated.
Burning
danger! 2508-0061
Step 3
Never touch the moving parts if the actuator is supplied with
compressed air.
Moving parts!
Moving parts!
2508-0060
Moving parts!
12

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the Parts list and service kits section.
4.2 Troubleshooting
Problem Possible cause Repair
Manual valve does not open when
actuator is turned counter-clockwise.
1. Diaphragm has stuck.
2. Diaphragm is not properly mounted
on the actuator.
3. Actuator is broken.
4. Incorrect flow direction in combination
with high fluid pressure.
1. Inspect diaphragm and replace it if
required.
2. Correct mounting. Some force must
be used to push the actuator into the
diaphragm.
3. Inspect and replace if required.
4. Correct flow direction or lower fluid
pressure.
Manual valve does not close when
actuator is turned clockwise.
1. Incorrect flow direction in combination
with high fluid pressure.
2. Actuator is broken.
1. Correct flow direction or lower fluid
pressure.
2. Inspect and replace id required.
Pneumatic valve does not open when
opened via a solenoid valve.
1. Diaphragm has stuck.
2. Diaphragm is not properly mounted
on the actuator.
3. Actuator is broken.
4. Compressed air supply is too low.
5. Pneumatic hose is damaged.
6. Solenoid valve fault or forced in wrong
position manually.
7. Incorrect flow direction in combination
with high fluid pressure.
1. Inspect diaphragm and replace it if
required.
2. Correct mounting. Some force must
be used to push the actuator into the
diaphragm.
3. Inspect and replace is required.
4. Check compressed air supply
pressure.
5. Replace pneumatic hose.
6. Check that the solenoid valve is not
operated manually. Replace solenoid
valve.
7. Correct flow direction or lower fluid
pressure.
Pneumatic valve is open all through
closed via the solenoid valve.
1. Solenoid valve fault.
2. Electrical cable is damaged.
3. Pneumatic system does not ventilate.
4. Incorrect flow direction in combination
with high fluid pressure.
1. Inspect and replace if required.
2. Replace electrical cable.
3. Check ventilation of pneumatic
system.
4. Correct flow direction or lower fluid
pressure.
Cleaning in CIP is not satisfactory. 1. Cleaning chemicals wrong type or too
low concentration.
2. Flow too low.
3. Poor draining.
4. Flow obstructed.
5. Diaphragm broken.
1. Analyse for correct chemicals and
concentration.
2. Increase flow.
3. Check drainabillity and turn valve if
required.
4. Check flow path.
5. Replace diaphragm.
13

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the Parts list and service kits section.
Problem Possible cause Repair
Water hammer. The flow direction is the same as the
closing direction.
The flow direction should be against the
closing direction.
Diaphragm has short length of line. 1. Incorrect materials for the application.
2. Media has too high temperature.
3. Air-air actuator has too high air
pressure.
4. Manual is “over-tightened”
1. Check materials compability (EPDM or
silicone).
2. Lower temperature or EPDM.
3. Reduce air pressure to 4 bar
4. Be careful not to tighten to hard.
External product leaking
(Telltale hole).
1. Diaphragm broken. 1. Replace diaphragm.
Valve leaking. 1. Clamp not properly mounted.
2. Too high fluid pressure. 1. Mount clamp or replace if broken.
2. Check that pressure does not exceed
design pressure.
Actuator leaking air. 1. Sealings in actuator worn out. 1. Replace actuator or change seals.
14

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 processing hot liquids
or when sterilising. Burning
danger!
2508-0061
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower diaphragm momentarily!
2508-0062
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.
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70 oC(158oF)
1kgNaOH 100 l water
2.2 lb NaOH +26.4 gal water = Cleaning agent.
2.2 l 33% NaOH 100 l water
0.6 gal 33% NaOH +26.4 gal water = Cleaning agent.
2. 0.5% by weight HNO3at 70 oC(158oF)
0.7 l 53% HNO3100 l water
0.2 gal 53% HNO3+26.4 gal water =Cleaning agent.
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 cleaning.
Always rinse!
Clean water Cleaning agents
Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
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 7
Autoclaving
The manually opened actuator can be autoclaved.
Max. temperature 130 °C
2508-0063
The pneumatic actuator can not be autoclaved.
2508-0064
17

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals in stock.
Check the valve for smooth operation after service.
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.
Burning
danger!
2508-0061
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.
Moving parts!
Cutting danger!
2508-0060
Moving parts!
18

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals in stock.
Check the valve for smooth operation after service.
Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal
working conditions in one shift.
Product wetted seals Actuator
Preventive
maintenance
Diaphragm replacement, see section 5.3
Diaphragm replacement
Special tools required for pneumatic actuator,
see section 5.5 Disassembly of actuator and 5.6
Assembly of actuator .
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
- Regular inspection for leakage and smooth
operation
- Keep a record of the actuator
- Use the statistics for planning of inspections
Replace after leakage
Lubrication Not necessary
Inside actuator use Kluber Paraliq GTE 703
But special tools reguired for pneumatic actuator (see
section 5.5 Disassembly of actuator and 5.6 Assembly
of actuator )
Clamps should be greased frequently at the thread with “molycole TP 42”
Negligence may result in damaged and stuck threads.
Recommended spare parts
Service kits (see spare parts - section 7 Parts list and service kits)
19

5 Maintenance
Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly.
Man = Manually activated
NC = Normally closed.
A/A = Air/air activated.
5.2 Dismantling the valve
Step 1
The actuator must be in the “open position” when dismantling the clamp.
Danger!
Always make sure that there is no product pressure in the pipeline before opening the valve.
Never service the valve when it is hot.
1. Supply compressed air to the actuator (only NC).
The manually handle is turned counter-clockwise.
2. Loosen and remove clamp.
3. Release compressed air (only NC).
4. Lift away the actuator and diaphragm.
5. Release compressed air (only NC)
6. The manually actuator spindle must be in the “closed position” to remove the diaphragm, which is done by rotating the
handle clockwise. The diaphragm is pushed away from the actuator housing.
7. Remove the diaphragm (see section 5.3 Diaphragm replacement )
Man. NC A/A
2508-0065 2508-0066 2508-0067
2508-0068 2508-0069
EPDM / Silicone Clamps
Valve Body
Tank Ou tlet
type 200
Shut off
type 200
2508-0070
2508-0071
Tank Ou tlet
type 300
Shut off
type 300
The ø12.7 / ½ inch and the ø25 mm / 1 inch is snapped onto the actuator rod.
The ø38 / 1½ inch is screwed onto the actuator spindle.
20