Alfalaval Unique 7000 Series User manual

ESE00213-ENUS4 2014-12
Original manual
Instruction Manual
Unique 7000 Series Valve - Standard and Reverse Acting

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 .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 10
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 12
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Troubleshooting ................................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling the valve ............................................................................. 20
5.3. Elastomer seat ring replacement ................................................................ 21
5.4. Assembly of valve ................................................................................. 22
5.5. Actuator bushing replacement .................................................................. 22
5.6. Dismantling of optional maintainable actuator ................................................. 22
5.7. Assembly of optional maintainable actuator ................................................... 22
5.8. Additional equipment ............................................................................. 23
6. Technical data ......................................................................................... 24
6.1. Technical data ..................................................................................... 24
7. Parts list and Service Kits ........................................................................... 25
7.1. Drawing ............................................................................................ 25
7.2. Unique 7000 TR2 - Shut-off-Valve .............................................................. 26
7.3. Unique 7000 TR2 - Change-over-Valve ........................................................ 28
7.4. Unique 7000 Elastomer plug seal - Shut-off-Valve ............................................ 30
7.5.Unique 7000 Elastomer plug seal - Change-over-Valve ...................................... 32
3
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1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique 7000 PN10
Ty p e
From serial number 5099880 to 29999999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2013-12-03
Place Date Signature
4
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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.
2.1 Important information
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!
!
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Indicates that special procedures must be followed to avoid serious personal injury.
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N
N
Indicates that special procedures must be followed to avoid damage to the valve.
N
N
O
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T
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E
E
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
5
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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
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2
2
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2
2
(
(
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)
)
:
:
Alfa Laval recommend only to use 43.5 PSI (3 bar)
support air on the spring side in all the Unique 7000
actuators, to ensure 145 PSI (10 bar) product pressure
without leakage.
Alfa Laval recommend max. 43.5 PSI
(3 bar)
Plastic adapter (Pos. 5) is always used on the new
design.
ø61/5inch
ø157.5 mm
TD 461-990
5
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0
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-
-
2
2
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1
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1
1
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)
)
:
:
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G
G
!
!
Max. 43.5 PSI (3 bar) “support air” on
spring side.
When using “support air” on spring side in all the Unique
7000 actuators, the pressure must N
N
O
O
T
T
exceed 43.5
PSI (3 bar).
ø61/7inch
When using Unique 7000 actuators with OD156 mm
with support air, a
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use the “steel adapter” (pos. 5).
Tighten the “steel adapter” with torque of 21 lbf-ft (30
Nm) and use Loctite 243.
ø156 mm
The actuator with OD156 mm is mainly used on valves
ISO76/DN80 – ISO101/DN100. The outer actuator
diameter = ø6 1/7 inch (156 mm).
TD 461-990
5
6
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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.
I
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:
:
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read the technical data thoroughly (See chapter 6 Technical data)
A
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release compressed air after use
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r
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touch the moving parts if the actuator is supplied with compressed air
N
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e
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r
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touch the valve or the pipelines when processing hot liquids or when sterilizing
N
N
e
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r
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dismantle the valve with valve and pipelines under pressure
N
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dismantle the valve when it is hot
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:
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dismantle the valve with valve and pipelines under pressure
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dismantle the valve when it is hot
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read the technical data thoroughly (See chapter 6 Technical data)
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release compressed air after use
N
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r
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touch the valve or the pipelines when processing hot liquids or when sterilizing
N
N
e
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r
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touch the moving parts if the actuator is supplied with compressed air
A
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rinse well with clean water after the cleaning
A
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handle lye and acid with great care
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:
:
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read the technical data thoroughly (See chapter 6 Technical data)
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release compressed air after use
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service the valve when it is hot
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service the valve with valve and pipelines under pressure
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stick your fingers through the valve ports if the actuator is supplied with compressed air
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touch the moving parts if the actuator is supplied with compressed air
7
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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).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery
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Alfa Laval cannot be held responsible for incorrect unpacking.
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:
:
1. Complete valve, shut off valve (RA) or change-over
valve (RA) (see steps 2a, 2b, 2c and 2d).
2. Delivery note.
3. Instruction manual.
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:
:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
TD 461-304_1
2
2
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b
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamp (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
TD 461-305_1
UP
2
2
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamp (19).
4. Valve plug (23).
5. 2 x upper valve body (26).
6. Valve seat (28).
7. Lower bonnet (33).
TD 461-306_1
UP
8
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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).
The valve is assembled before delivery, if it is supplied with fittings.
2
2
d
d
C
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-
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamp (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve body (26).
7. 2 x valve seat (28).
8. Lower bonnet (33).
TD 461-307_1
UP
S
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p
3
3
Remove possible packing materials from the valve/valve parts.
Inspect the valve/valve parts for visible transport damages.
Avoid damaging the valve/valve parts.
9
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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.
3.2 General installation
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read the technical data thoroughly.
See chapter 6 Technical data
A
A
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release compressed air after use.
C
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A
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U
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O
O
N
N
Alfa Laval cannot be held responsible for incorrect installation.
S
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p
2
2
N
N
e
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v
v
e
e
r
r
touch the moving parts if the actuator is supplied with
compressed air.
Air
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p
p
a
a
r
r
t
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s
s
!
!
Air
S
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p
p
3
3
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammer.
Shock in the actuator must n
n
e
e
v
v
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e
r
r
occur.
A
A
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o
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i
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!
!
Inlet
Inlet
S
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p
p
4
4
Avoid stressing the valve.
P
P
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:
:
- Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
R
R
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o
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f
f
d
d
a
a
m
m
a
a
g
g
e
e
!
!
10
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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.
3.3 Welding
S
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1
A
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install valves with more than one valve body so that the
seals between the valve bodies can be replaced. Do not weld
more than one valve body into the system.
Valve size A (inch) B (inch)
1” * 24.8
1½” * 27.6
2” * 29.5
2½” * 29.1
3” * 31.5
4” * 31.1
* Depending on body combination and piping solution.
B (incl. top unit)
A*
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2
2
Assemble the valve in accordance with the steps on page 22.
P
P
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h
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w
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a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
S
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p
p
3
3
P
P
r
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-
-
u
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c
c
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k
:
:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
P
P
a
a
y
y
s
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p
p
e
e
c
c
i
i
a
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l
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a
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e
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n
n
t
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i
i
o
o
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o
o
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t
h
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e
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w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
Air
Air
Open/close!
11
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