Alfalaval Unique 7000 Series User manual

ESE02025ENUS 2011-05
Unique 7000 Series - Manually Operated Valve
Instruction Manual
TD 422-031

2

Alfa Laval
Company Name
Bjarne Søndergaard
Declaration of Conformity
The designating company
Designation
is in conformity with the following directive:
- Machinery Directive 98/37/EEC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure
Module A.
hereby declare that
Denomination Type Year
Address
Phone No.
Name
Title
Company Signature
Manager, Product Centres,
Compact Heat Exchangers & Fluid Handling
Alfa Laval Kolding
Albuen 31, DK-6000 Kolding, Denmark
[phone]
 3
Unique 7000 Series Valve Manually Operated

4

 5
1. Safety ..................................................................................................... 6
1.1 Important information ........................................................................ 6
1.2 Warning signs ................................................................................... 6
1.3 Safety precautions ............................................................................ 7
2. Installation ............................................................................................. 8
2.1. Unpacking/Delivery .......................................................................... 8
2.2. General installation ........................................................................... 9
2.3. Welding.......................................................................................... 10
3. Operation ............................................................................................. 11
3.1 Operation ........................................................................................ 11
3.2 Trouble shooting ............................................................................. 13
3.3 Recommended cleaning ................................................................. 14
4. Maintenance ........................................................................................ 16
4.1 General maintenance ...................................................................... 16
4.2 Dismantling of valve ........................................................................ 18
4.3 Plug seal replacement ..................................................................... 18
4.4 Assembly of valve ........................................................................... 18
5. Technical data ...................................................................................... 19
5.1 Technical data ................................................................................. 19
6. Parts List and Service Kits ................................................................. 20
6.1 Unique 7000 Series Valve ............................................................... 20
Table of contents
The information contained herein is correct at the time of issue but may be subject to change without prior notice.

6
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the valve!
WARNING!
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION!
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE!
Indicates important information to simplify or clarify practices.
1.1 Important information
1.2 Warning signs
1. Safety
General warning:
Caustic agents:

7
Warning!
When using “support air” on spring side in all the Unique 7000
actuators, the pressure must NOT exceed 3 bar (43.5 psi.)
When using Unique 7000 actuators with OD156mm (6 1/7 inch)
with support air, always use the “steel adaptor” (pos. 5).
Tighten the “steel adaptor” with torque of 30 Nm (23 lbf-ft) and
use Loctite 243.
The actuator with OD156mm is mainly used on valves
ISO76/DN80 - ISO101/DN100.
The outer actuator diameter = 6 1/7 inch.
5
TD461-987
Ø156
Max. 3 bar (43.5 psi)
“support air” on spring
side.
Ø156 (6 1/7 inch.)
Installation
- Always read the technical data thoroughly (see chapter 5).
- Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
- Never dismantle the valve with valve and pipelines under pressure.
- Never dismantle the valve when it is hot.
Operation
- Never dismantle the valve with valve and pipelines under pressure.
- Never dismantle the valve when it is hot.
- Always read the technical data thoroughly (see chapter 5).
- Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
- Always rinse well with clean water after the cleaning.
Always handle lye and acid with great care.
Maintenance
- Always read the technical data thoroughly (see chapter 5).
- Never service the valve when it is hot.
- Never service the valve with valve and pipelines under pressure.
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.
1. Safety 1.3 Safety precautions

8
2. 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.
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve or change-over valve.
2. Delivery note.
3. Instruction Manual.
2.1 Unpacking/Delivery
Step 2a
Shut-off valve:
1. Complete handle.
2. Bonnet (20)
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
Step 2b
Change-over valve:
1. Complete handle.
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 461-585
TD 461-586_1
UP
Step 2c
Shut-off valve - Reverse Acting:
1. Complete handle.
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 461-587_1
UP

9
Step 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.
2. Installation 2.1 Unpacking/Delivery
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.
The valve is supplied as separate parts as standard (for welding).
Step 2d
Change-over valve - Reverse Acting:
1. Complete handle.
2. Bonnet (20)
3. 4 x clamp (19).
4. Upper valve plug (34).
5. Lower valve body (35).
6. 3 x upper valve body (26).
7. 2 x valve seat (28).
8. Lower bonnet (33).
TD 461-588_1
UP

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2. Installation 2.2 General 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.
Step1
- Always read the technical data thoroughly (see chapter 5).
CAUTION!
Alfa Laval cannot be held responsible for incorrect installation.
Risk of damage!
Inlet
Avoid water
hammer!
Inlet
Step 2
Never touch the moving parts during operation
Step 3
It is recommended to install the valve so that the flow is
against the closing direction to avoid water hammer.
Step 4
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
TD 461-590
TD 461-591
Moving parts!
TD 461-589

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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.
Step 1
Always 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.
Measurement A is depending on body combination and
piping solution.
Please see actual PD-sheet for further information
Step 2
Assemble the valve in accordance with the steps in section 4.4.
Pay special attention to the warnings!
Step 3
Pre-use check:
1. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings!
2. Installation
2.3 Welding
TD 461-592
TD 461-593
TD 461-614
TD 461-594
A

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3.1 Operation
3. Operation
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.
Step 1
- Always read the technical data thoroughly (see chapter 5).
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.
Step 3
Never touch the moving parts during operation.
Step 4
Lubrication of valves:
1. Ensure smooth movement between lip seal (25)
and plug stem (23, 27).
2. Lubricate with Klüber Paraliq GTE 703 if necessary.
(see section 4.1)
Change-over valveShut-off valve
Burning danger!
Moving parts!
TD 461-595
TD 461-597
TD 461-615
TD 461-589

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3.1 Operation 3. Operation
Step 5
Lubrication of crank mechanism
1. Ensure smooth movement of the crank mechanism
(the crank is lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
TD 461-598

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3. Operation 3.2 Trouble shooting
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section
NOTE!
Study the maintenance instructions carefully before
replacing worn parts. - See section 4.1!
External product leakage Worn or product affected lip - Replace the seals
seal and/or O-ring - Replace with seals of a
different rubber grade
Internal product leakage - Worn or product affected - Replace the seal
plug seal - Replace with a seal of a
different rubber grade
- Product deposits on - Frequent cleaning
the seat and/or plug
- Product pressure exceeds - Replace with a high pressure actuator
actuator specification - Use auxiliary air on the spring side
- Reduce product pressure
Water hammer The flow direction is the The flow direction should be
same as the closing direction against the closing direction
The valve does not Product pressure exceeds Reduce pressure
open/close specification
Problem Cause/result Repair

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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 1
Always handle lye and acid with great care.
Step 2
Never touch the valve or the pipelines when sterilizing.
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily!
Step 4
Examples of cleaning agents:
Use clean water, free from clorides.
Caustic danger!
Always use Always use
rubber gloves! protective goggles!
Change-over valve
Shut-off valve
Lift/lower
valve plug
2.2 lb + 26.4 gal = Cleaning agent
NaOH water
0.6 gal + 26.4 gal = Cleaning agent
33% NaOH water
0.2 gal + 100 l = Cleaning agent
53% HNO3 water
4
2. 0.5% by weight HNO3 at 158o F
Burning danger!
TD 461-595
TD 461-599
TD 461-600
1. 1% by weight NaOH at 158o F
3. Operation
3.3 Recommended cleaning

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3. Operation 3.3 Recommended cleaning
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 rules/directives.
Always rinse!
Clean water Cleaning agents

17
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.
Step 1
- Always read the technical data thoroughly (see chapter 5).
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.
Step 3
Never stick your fingers through the valve ports.
Step 4
Never touch the moving parts during operation.
Atmospheric
pressure
required!
Burning danger!
Cutting danger!
TD 461-602
TD 461-589
Moving parts!
TD 461-589
4. Maintenance
4.1 General maintenance

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4.1 General maintenance
4. Maintenance
Maintain the valve regularly.
Study the instructions carefully.
Always keep spare rubber seals and lip seals stock.
Check the valve for smooth operation after service.
Pre-use check:
1. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Recommended spare parts
Service kits (see chapter 6)
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
Preventive Replace after
maintenance 12 months depending
on working conditions
Maintenance after Replace at the
leakage (leakage end of the day
normally starts slowly)
Planned - Regular inspection
maintenance for leakage and
smooth operation
- Keep a record of
the valve
- Use the statistics for
planning of inspections
Replace after leakage
Lubrication Before fitting
Klüber Paraliq GTE 703
or similar USDA H1
approved oil/grease
TD 461-589

19
TD 461-959
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
Step 1a
Shut-off valve:
1. Remove cap, loosen screw and remove the washer by
sliding it sideways.
2. Loosen and remove clamp.
3. Lift away the crank.
4. Remove valve plug.
5. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
Pay special attention to the warnings!
Note! For plug seal replacement please see section 4.3.
TD 461-601
Step 1b
Change-over valve:
1. Loosen and remove lower clamp.
2. Lift away the crank and upper valve body.
3. Remove cap, loosen screw and remove the washer by
sliding it sideways.
4. Loosen and remove upper clamp.
5. Lift away the crank.
6. Remove valve plug.
7. Remove seat and O-rings.
8. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet. See drawing, step 1a).
Pay special attention to the warnings!
Note! For plug seal replacement please see section 4.3.
4.2 Dismantling of valve
4.3 Plug seal replacement
4.4 Assembly of valve
4. Maintenance
TD 461-607_1
UP
Step 1c
Shut-off valve - Reverse Acting:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring from lower body.
3. Loosen and remove middle clamp.
4. Lift away the crank and upper valve body.
5. Remove cap, loosen screw and remove the washer by
sliding it sideways.
6. Loosen and remove upper clamp.
7. Remove valve plug
8. Remove seat and O-rings.
9. Remove O-.ring, lip seal and bushing in bonnet.
(use bushing tool and rubber mallet. See drawing, step 1a).
Pay special attention to the warnings!
Note! For plug seal replacement please see section 4.3. TD 461-608_1
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4.4 Assembly of valve
Reverse order of 4.2, Dismantling of valve.
Lubricate O-ring (21) and lip seal (25) with Klüber Paraliq GTE 703.
Remember to tighten spindle and plug with a torque M = 23 lbf-ft (30 Nm) (Use two 17 mm spanners)
If there are vibrations in the pipeline Alfa Laval recommend to use loctite no. 243.
Note!
Do not forget to screw in lower set screw 7 when assembling the valve. It acts as a stroke stop. Without
this screw the valve can be opened so far that the crank comes off. In some valve sizes the flats on the
plug stem may enter into the lip seal, which will then leak.
4.3 Plug seal replacement
1. Remove old seal ring using a knife, screwdriver or similar.
Be careful not to damage metal parts.
2. Pre-mount plug seal without pressing it into the groove.
3. Squeeze plug seal into the groove using opposite pressure points.
4. Release compressed air behind plug seal.
Step 1d
Change-over valve - Reverse Acting:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring.
3. Loosen and remove clamp between lower and middle valve body.
4. Lift away the actuator and upper + middle valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove lower valve plug.
7. Release compressed air (only NC).
8. Remove lower seat and O-rings.
9. Supply compressed air to the actuator (only NO).
10. Loosen and remove clamp between middle and upper valve body.
11. Remove middle valve body and upper seal with O-rings.
12. Release compressed air (only NO).
13. Loosen and remove upper clamp.
14. Remove upper valve body.
15. Unscrew nad remove upper valve plug.
16. Remove O-ring, lip seal and bishing in bonnet.
(use bushing tool and rubber mallet. See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please see section 4.3.
UP
UP
TD 462-003_2
UP