Alfalaval Unique 7000 Series User manual

TD 470-008
ESE00774ENUS1 2008-10
Unique 7000 Series 6-inch Valve
Instruction Manual

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 6-inch 2008

4

The information contained herein is correct at the time of issue but may be subject to change without prior notice.
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
4.5 Actuator bushing replacement ........................................................ 18
5. Technical data...................................................................................... 19
5.1 Technical data................................................................................. 19
6. Parts List and Service Kits................................................................. 21
6.1 Unique 7000 Series 6-inch Valve..................................................... 21
Table of contents

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
Installation
- Always read the technical data thoroughly (see chapter 5).
- 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 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).
- Always release compressed air after use.
- Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
- Never touch the moving parts if the actuator is supplied with compressed air.
- 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).
- Always release compressed air after use.
- Never service the valve when it is hot.
- Never service the valve with 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.
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
TD 470-009
36
22
71
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 assembled before delivery.
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve, shut off valve.
2. Delivery note.
3. Instruction Manual.
2.1. Unpacking/Delivery
Step 2
Shut-off valve:
Complete actuator.
Clamp (71).
Valve plug (36).
Valve body (22).

9
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).
- Always release compressed air after use.
CAUTION!
Alfa Laval cannot be held responsible for incorrect installation.
Risk of damage!
Avoid water
hammer!
Inlet
Step 2
Never touch the moving parts if the actuator is supplied
with compressed air.
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.
Air
Air
Moving parts!
TD 470-010
TD 470-011
TD 470-012

10
Step 1
* If ThinkTop is mounted, add 9.8 inch.
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 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. 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!
2. Installation
2.3. Welding
Open/close!
Air
Air
38.6 inch*
TD 470-013
TD 470-020
TD 470-014

11
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).
- 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.
Step 3
Never touch the moving parts if the actuator is supplied
with compressed air.
Step 4
Lubrication of valves:
1. Ensure smooth movement between O-ring (73)
and plug stem (36).
2. Lubricate with Klüber Paraliq GTE 703 if necessary.
(see section 4.1)
Air
Air
Burning danger!
Moving parts!
TD 470-015
TD 470-010
TD 470-016
36
73

12
3.1 Operation 3. Operation
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator
(the actuator is lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
TD 470-017

13
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 O-ring - Replace the seals
and/or gasket - Replace with seals of a
different rubber grade
Internal product leakage - Worn or product affected - Replace the seal/plug
plug seal - Replace with a plug of a
different rubber grade
- Product deposits on - Frequent cleaning
the seat and/or plug
- Product pressure exceeds - Use auxiliary air on the spring side
actuator specification - Reduce product pressure
Water hammer The flow direction is the - The flow direction should be
same as the closing direction against the closing direction
- Throttle air release of solenoid in
top unit
The valve does not Product pressure exceeds - Use auxiliary air on the spring side
open/close actuator specification - Reduce product pressure
Problem Cause/result Repair

14
3. Operation
3.3 Recommended cleaning
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!
2.2 lb + 26.4 gal = Cleaning agent.
NaOH water
0.6 gal + 26.4 gal = Cleaning agent.
33% NaOH water
0.2 gal + 26.4 gal = Cleaning agent.
53% HNO3water
4
1. 1% by weight NaOH at 158°F
2. 0.5% by weight HNO3at 158°F
Burning danger!
TD 470-015
TD 470-018

15
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.
3. Operation 3.3 Recommended cleaning
Always rinse!
Clean water Cleaning agents

16
4.1 General maintenance 4. 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.
Step 1
- Always read the technical data thoroughly (see chapter 5).
- Always release the compressed air after use.
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 if the
actuator is supplied with compressed air.
Step 4
Never touch the moving parts if the actuator is supplied
with compressed air.
Atmospheric
pressure
required!
Air
Burning danger!
Cutting danger!
Air
Air
Air
Moving parts!
TD 470-019
TD 470-010
TD 470-010

17
4. Maintenance 4.1 General 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. 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
Open/close!
Air
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 Actuator
seals bushings complete
Preventive Replace after Replace after
maintenance 12 months depending 5 years depending
on working conditions on working conditions
Maintenance after Replace at the Replace when
leakage (leakage end of the day possible
normally starts slowly)
Planned - Regular inspection - Regular inspection
maintenance for leakage and for leakage and
smooth operation smooth operation
- Keep a record of - Keep a record of
the valve the actuator
- Use the statistics for - Use the statistics for
planning of inspections planning of inspections
Replace after leakage Replace after leakage
Lubrication Before fitting Before fitting
Klüber Paraliq GTE 703 Molykote Longterm 2 plus
or similar USDA H1
approved oil/grease
TD 470-014

18
4. Maintenance
4.2 Dismantling of valve
4.3 Plug seal replacement
4.4 Assembly of valve
4.5 Actuator bushing replacement
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
4.2
Shut-off valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Release compressed air (only NC).
4. Lift away the actuator.
5. Unscrew and remove valve plug.
6. Remove gasket, O-ring and bushing in yoke.
Pay special attention to the warnings!
Note! For plug seal replacement please see section 4.3.
TD 470-021
4.3
TR2 seat ring replacement
1. Place the plug element on a firm support.
2. Using a utility knife, partially AND CAREFULLY cut through the upper ring
portion of the TR2 plug avoiding contact with stainless steel stem.
3. Force apart both cut ends of the plug for removal from stem.
4. TR2 plugs are installed by applying pressure. (Pressure can be applied by hand.)
5. Pressure until the TR2 plug snap on to the stem.
6. Examine seat assembly to be sure the TR2 plug is properly mounted,
holding the seat assembly in one hand - rotate the TR2 plug.
(For proper CIP cleaning the TR2 plug should turn freely on the stem.)
4.4
Assembly of valve
Reverse order of 4.2, Dismantling of valve.
Lubricate gasket (21) and O-ring (25) with Klüber Paraliq GTE 703.
4.5
1. Unscrew and remove top plate and yoke.
2. Remove bushings and O-rings.
3. Lubricate O-rings with Molykote Longterm 2 plus
before fitting.
4. Fit bushings and O-rings.
TD 470-022
6
72
7

19
5. Technical data 5.1 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.
Data - valve/actuator
Max. product pressure....................................................... 145 psi (1000 kPa) (10 bar)
Min. product pressure........................................................ Full vacuum (depending on product specifications)
Temperature range ............................................................ 14o F to + 284o F (standard EPDM seal)
14o F to + 170o F (TR2 seal)
Air pressure, actuator ........................................................ 72.5 to 101.5 psi (500 to 700 kPa) (5 to 7 bar)
Materials - valve/actuator
Product wetted steel parts................................................. AISI 316L (internal Ra < 32 µ inch)
Other steel parts................................................................ AISI 304
Plug seal............................................................................ EPDM / PTFE (TR2)
Optional elastomer plug seal.............................................. EPDM / Buna, SFY
Other product wetted seals ............................................... EPDM (standard)
Optional product wetted seals ........................................... Buna and SFY
Other seals ........................................................................ Buna

20