Alfalaval Unique 7710 User manual

Instruction Manual
Unique 7710 Regulating Valve
22050000
ESE00480-ENUS2 2012-02
Original manual

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 ................................................................................ 9
3.3. Welding ............................................................................................ 10
3.4. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation .......................................................................................... 12
4.2. Troubleshooting ................................................................................... 14
4.3. Recommended cleaning ......................................................................... 15
5. Maintenance ........................................................................................... 17
5.1. General maintenance ............................................................................. 17
5.2. Dismantling of valve .............................................................................. 19
5.3. Elastomer seat ring replacement ................................................................ 19
5.4. Assembly of valve ................................................................................. 19
5.5. Positioner end ..................................................................................... 20
5.6. Actuator bushing replacement .................................................................. 20
5.7. Dismantling of optional maintainable actuator ................................................. 20
5.8. Assembly of optimal maintainable actuator .................................................... 21
5.9. Additional equipment ............................................................................. 21
6. Technical data ......................................................................................... 22
6.1. Technical data ..................................................................................... 22
7. Unique 7710 Regulating Valve ...................................................................... 23
7.1. Unique 7710 Regulating Valve ................................................................... 23
7.2. Unique 7710 Regulating Valve ................................................................... 24
7.3. Maintanable actuator ............................................................................. 26
3

1 EC Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Unique 7710 Series Valve Regulating Valve
Denomination Type Year
is in conformity with the following directives:
-Mac
hinery Directive 98/37/EEC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.
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 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 thespringsideinalltheUnique7000
actuators, to ensure 145 PSI (10 bar) product pressure
without leakage.
Plastic adapter is always used on the new design.
Alfa Laval recommend max. 43.5 PSI
(3 bar)
ø6 1/5 inch
ø157.5 mm
TD 461-989
Actuators marked with year 2006-2011 (Old actuator
design):
WARNING!
When using “support air” on spring side in all the Unique
7000 actuators, the pressure must NOT exceed 43.5
PSI (3 bar).
Max. 43.5 PSI (3 bar) “support air” on
spring side.
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. ø6 1/7 inch
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 461-989
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 and 2b).
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).
6. Spring connection piece(42).
7. Positioner yoke (44).
8. Spring (46)
9. Positioner (47)
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.
8

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.
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!
Step 3
Avoid stressing the valve:
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
9

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
Assemble the valve in accordance with the steps in section 4.4
Pay special attention to the warnings! i
Step 2
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!
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.
3.4 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
11

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 sterilizing. Burning danger!
Step 3
Never touch the moving parts if the actuator is supplied with
compressed air. Moving parts!
Air
Step 4
Lubrication of actuator
1. Ensure smooth movement between lip seal (25).
2. Lubricate with Klüber Paraliq GTE 703 if necessary. (See
seciton 4.1)
Shut-off Valve
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.
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate O-ring(s) with Molykote Longterm 2 plus if necessary.
13

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 5.1!
Problem Cause/result Repair
External product leakage Worn or product affected diaphragm stem
seal and/or seal ring
- Replace the seals or diaphragm
- 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
- 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
Deviation in the flow regulation - Mechanical parts have come loose
(vibrations) - Tighten and adjust
Actuator does not regulate - No air
-Actuatorerrors
-Positionererrors
Check air supply
- Return the actuator to the supplier
- Check positioner (see positioner
instruction)
14

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 sterilizing.
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
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
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.
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.
16

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.
Cutting danger!
Air
Step 4
Never touch the moving parts if the actuator is supplied with
compressed air. Moving parts!
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.
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
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!
Open/close!
Recommended spare parts
Service kits (see chapter 7)
18

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 of valve
Step 1
1a
Dismantling of valve:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Replace compresed 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).
Pay special attention to the warnings!
TD 461-837
Note!
Be careful not to damage the
bushing.
Note! For plug seal replacement please see page 19.
5.3 Elastomer seat ring 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.
1
4
3
2TD461309_3
5.4 Assembly of valve
Reverse order of 5.2, 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)
19

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section. Handle scrap correctly.
A/A = Air/air activated.
Service tool: See Spare Parts.
5.5 Positioner end
1. Remove the air hose connections of the positioner (47) and the actuator.
2. Loosen the screws and lift off the positioner from its yoke (44).
3. Remove the positioner spring (46) and unscrew the spring connection
piece (42) from the actuator spindle.
4. Unscrew the positioner yoke (44) from the cylinder.
5. Remove the guide ring (45) and the O-ring (8).
5.6 Actuator bushing replacement
1. Unscrew and remove O-rings.
2. Lubricate O-rings with Molykote Longterm 2 plus before fitting.
3. Fit bushings and O-rings. Tighten brushing with a torque = 7 lbf-ft (10 Nm).
Be careful not to overtighten.
8
6
7
5.7 Dismantling of optional maintainable actuator
Rotate cylinder with service tool
1. Rotate cylinder.
2. Remove lock wire (10) and pull away cylinder (1).
3. Unscrew nuts (18) and remove yoke (13).
4. Unscrew bottom bushing (6).
5. Remove stem (2) with O-ring (3) and spring assembly (14).
6. Remove O-rings and support disc.
Note! The A/A actuator has no spring assembly.
TD 461-033
20