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
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