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

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique 7000 PN10
Type
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

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
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 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
Actuators marked with year 2012 (New actuator
design):
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. ø6 1/5 inch
ø157.5 mm
TD 461-990
5
Actuators marked with year 2006-2011 (old actuator
design):
WARNING!
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 NOT exceed 43.5
PSI (3 bar). ø6 1/7 inch
When using Unique 7000 actuators with OD156 mm
with support air, always 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

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 damagetothevalveareavoided.
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 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 6 Technical data)
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 6 Technical data)
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
7

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
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
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.
Step 2
2a
Shut-off valve:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
TD 461-304_1
2b
Change-over valve:
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
2c
Shut-off valve - Reverse Acting:
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

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.
2d
Change-over valve - Reverse Acting:
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
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.
9

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
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.
Air
Moving parts!
Air
Step 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 never occur.
Avoid water
hammering!
Inlet
Inlet
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
10

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
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.
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*
Step 2
Assemble the valve in accordance with the steps on page 22.
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!
Air
Air
Open/close!
11

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.
3.4 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 wear 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 wear parts must be taken care of in agreement with local regulations
•Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside 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
12

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.
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 the pipelines when processing hot liquids
or when sterilising. Burning danger!
Step 3
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
13

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.
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).
Shut-off valve Change-over valve
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.
14

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section.
4.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See section 4.1!
Problem Cause/result Repair
External product leakage Worn or product affected lip
seal and/or O-ring
- Replace the seals
- Replace with seals of a
different rubber grade
Internal product leakage - Worn or product affected
plug seal - Replace the seal - Replace with a seal of a
different rubber grade
- Product deposits on
the seat and/or plug - Frequent cleaning
- Product pressure exceeds
actuator specification - Replace with a high pressure actuator - Use auxiliary air on the spring side
(do not exceed 3 bar)
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
- The flow direction should be
against the closing direction
- Throttle air release of solenoid in
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
- Reduce product pressure
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.
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 sterilising.
Burning danger!
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily!
Shut-off valve Change-over valve
Step 4
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 158oF
2.2 lb
NaOH +26.4 gal water =Cleaning agent.
+=
Cleaning agent.
0.6 gal
33% NaOH
26.4 gal
water
2. 0.5% by weight HNO3at 158oF
+=
Cleaning agent.
0.2 gal
53% HNO3
26.4 gal
water
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 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.
Always rinse!
Clean water Cleaning agents
Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
17

5 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.
5.1 General maintenance
Step 1
Always read the technical data thoroughly.
See chapter 5.
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.
Atmospheric
pressure
required!
Burning danger!
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Cutting danger!
Air
Step 4
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
18

5 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.
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 bushings complete
Preventive
maintenance
Replace after
12 months depending
on working conditions
Replace after
5 years depending
on working conditions
Maintenance after
leakage (leakage
normally starts slowly)
Replace at the
end of the day
Replace when
possible
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
Before fitting
Klüber Paraliq GTE 703
or similar USDA H1
approved oil/grease
Before fitting
Molykote Longterm 2 plus
Pre-use check: Air
Open/close!
Air
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!
Recommended spare parts
Servicekits(seepage25)
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
5.2 Dismantling the valve
Step 1
1a
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 O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings! TD 461-959
Note!
Be careful not to damage the
bushing.
Note! For plug seal replacement please see page 21.
1b
Change-over valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove lower clamp.
3. Release compressed air (only NC).
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NO).
6. Unscrew and remove valve plug.
7. Release compressed air (only NO).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing 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 page 21.
UP
TD 461-331_1
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 actuator and upper valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove valve plug.
7. Release compressed air (only NC).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing 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 page 21.
UP
UP
TD 462-127_1
20