Alfalaval Unique DV-ST UltraPure Operation instructions

ESE01752-EN122022-10
Originalmanual
InstructionManual
UniqueDV-STUltraPure-Manual:forvalvesizesDN8toDN100(¼”to4”)

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.Generalinformation.........................................................................4
1.1.Valvedesign.......................................................................................4
2.Safety..........................................................................................5
2.1.Importantinormation.............................................................................5
2.2.Warningsigns.....................................................................................5
2.3.Saetyprecautions................................................................................6
3.Installation....................................................................................7
3.1.Unpacking/delivery...............................................................................7
3.2.Generalinstallation................................................................................7
3.3.Installationangleonsel-drainingposition......................................................8
3.4.Drainability.........................................................................................8
3.5.Welding............................................................................................8
3.6.Mountingothebonnet..........................................................................8
3.7.Recyclinginormation.............................................................................9
4.Maintenance..................................................................................10
4.1.Generalmaintenance.............................................................................10
4.2.Diaphragmmaintenance.........................................................................10
4.3.Replacingthediaphragm........................................................................10
4.4.Travelstopadjustment...........................................................................13
5.Technicaldata................................................................................16
5.1.Size.................................................................................................16
5.2.Temperaturerecommendationsandservicelietime..........................................16
3

1Generalinformation
1.1Valvedesign
1Countersinkscrew
2Handwheel
3Coupling
4Positionnut
5Spindle
6Nuts
7Washers
8Yoke
9Thrustwasher*
10Diaphragmholder
11Compressor
12Diaphragm
13Valvebody
14Fasteners
*)Remembertoinsert"thrustwasher"(9)during
installationothediaphragmholderontothespindle
4

2Safety
Unsafepracticesandotherimportantinformationareindicatedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
2.1Importantinformation
Always Always
Alwaysr r read ead eadthis this thismanual manual manualbeor beor beore e eusing using usingthe the thevalve! valve! valve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbeollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbeollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinormationtosimpliyorclariyprocedures.
2.2Warningsigns
General General
Generalwar war warning: ning: ning:
Caustic Caustic
Causticagents: agents: agents:
5

2Safety
Allwarningsinthismanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseriouspersonalinjuryand/ordamagetothevalveareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Operation: Operation:
Operation:
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Nevertouchmovingpartsitheactuatorissuppliedwithcompressedair
Always Always
Alwaysrinsewellwithcleanwateratercleaning
Always Always
Alwayshandlelyeandacidwithgreatcare
Maintenance: Maintenance:
Maintenance:
Never Never
Neverservicethevalvewhenitishot
Never Never
Neverservicethevalvewiththeandpipelinesunderpressure
Never Never
Neverputyouringersthroughthevalveportsitheactuatorissuppliedwithcompressedair
Never Never
Nevertouchmovingpartsitheactuatorissuppliedwithcompressedair
T T
Transportation: ransportation: ransportation:
Always Always
Alwayscheckthatallconnectionsaredisconnectedbeoreattemptingtoremovethevalveromtheinstallation
Always Always
Alwaysdrainliquidromvalvesbeoretransportation
Always Always
Alwaysusedpre-deinedlitingpointsigiven
Always Always
Alwaysensurethatthevalveisadequatelysecuredduringtransportation-ispeciallydesignedpackagingmaterialis
available,itmustbeused
6

3Installation
Theinstructionmanualispartofthedelivery.Studytheinstructionscarefully.
Theitemsrefertothepartslistandtheservicekitssection.
Thevalveissuppliedasseparatepartsasstandardforwelding).
Thevalveisassembledbeforedelivery,ifitissuppliedwithfittings.
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
AlaLavalcannotbeheldresponsibleorincorrectunpacking.
Check Check
Checkthe the thedelivery delivery deliveryor: or: or:
1.Completevalve.
2.Deliverynote.
Step Step
Step2 2 2
1.Removeanypackingmaterialsromthevalve/valveparts.
2.Inspectthevalve/valvepartsorvisibletransportationdamage.
3.Avoiddamagingthevalve/valveparts.
3.2Generalinstallation
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatathoroughly.
CAUTION CAUTION
CAUTION
AlaLavalcannotbeheldresponsibleorincorrectinstallation.
Always Always
Alwaysreadthetechnicaldatathoroughly.
CAUTION CAUTION
CAUTION
AlaLavalcannotbeheldresponsibleorincorrectinstallation.
Avoidstressingthevalve.
Payspecialattentionto:
-Vibrations.
-Thermalexpansionothepipelines.
-Excessivewelding.
-Overloadingothepipelines.
Risk Risk
Risko o odamage! damage! damage!
-Fordrainingthediaphragmvalveandpipeline,anappropriateinstallationpositionmustbeprovided.
-Variableinstallationposition.Forsel-draining,seethedataontheinstallationangle.
-Fordiaphragmvalveswithweldends,removethebonnetanddiaphragmromthevalvebodybeorewelding.
7

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
3.3Installationangleonself-drainingposition
T T
Table able able1. 1. 1.Drain Drain Drainangle angle anglex x x
Port Port
Portsize size size
DN DN
DNInch Inch Inch
ASME ASME
ASME
BPE BPE
BPEISO ISO
ISO2037 2037 2037DIN DIN
DIN11866 11866 11866
(Series (Series
(SeriesA) A) A)
ISO ISO
ISO1127 1127 1127
(Series (Series
(SeriesB) B) B)
8¼”37°27°27°22°
10¾”33°28°28°31°
15½”32°23°23°18°
20¾”26°23°23°15°
251”22°25°21°20°
401½”24°24°22°18°
502”24°24°23°20°
652½”20°22°19°15°
803”22°25°22°15°
1004”14°13°8°8°
3.4Drainability
Properdrainabilityinhorizontallylevelinstalledpipesrequiresmountingothevalveatthecorrectangle.Seetablebelow.
Toensureproperdrainability,thevalvemustbemountedatthecorrectangle.Properinstallationistheresponsibilityothe
systeminstallerand/oruser.
3.5Welding
Step Step
Step1 1 1
All All
Allwelding welding weldingshould should shouldbe be bedone done doneby by byqualiied qualiied qualiiedpersonnel. personnel. personnel.
Disassemblethebonnetandthediaphragmromthevalvebody.SeeReplacingtheDiaphragmordetails.
Step Step
Step2 2 2
Perormtheweldingprocedureonthebodyaccordingtostandardindustrialpractices.
Step Step
Step3 3 3
Reassemblethebonnetandthediaphragmtothevalvebody.
Step Step
Step4 4 4
Testthevalveorproperoperationbeoreinstalling.
3.6Mountingofthebonnet
ForT-valves,Tandemvalves,TankoutletvalvesandBlockvalves,pleasenotethatthebonnetismountedusingstudsandnuts
insteadoboltsandnuts.
8

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
3.7Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsowood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbere-used,recycledorusedorenergyrecovery
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentormaterialrecycling
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearpartsinthemachinearereplaced
-Allmetalpartsshouldbesentormaterialrecycling
-Wornoutordeectiveelectronicpartsshouldbesenttoalicensedhandlerormaterialrecycling
-Oilandallnon-metalwearpartsmustbedisposedoinagreementwithlocalregulations
• •
•Scrapping Scrapping Scrapping
-Atendouse,theequipmentmustberecycledaccordingtorelevant,localregulations.Besidestheequipmentitsel,any
hazardousresiduesromtheprocessliquidmustbetakenintoconsiderationanddealtwithinapropermanner.Whenin
doubt,orintheabsenceolocalregulations,pleasecontactyourlocalAlaLavalsalescompany
9

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Generalmaintenance
ApplyKlüberpasteUH184-201oranequivalentmediumtothespindleduringserviceinordertopreventgallingand/or
excessivewear.
Remembertoinsert"thrustwasher"(9)duringinstallationothediaphragmholderontothespindle
4.2Diaphragmmaintenance
Generally,theonlyroutinemaintenancerequiredisthereplacementothediaphragm.
Diaphragm Diaphragm
Diaphragmr r replacement eplacement eplacementr r routine outine outine
Dependingonthemedium,thepressure,temperatureandcycle(durationandtemperature)osteamsterilisationbetween
processruns,determinestheoptimumchangecycleothediaphragm.
4.3Replacingthediaphragm
Beor Beor
Beore e eservicing servicing servicingany any anyinstalled installed installedvalve valve valveyou you youmust: must: must:
-depressurisethesystem
-openthevalve
-purgethevalve
Note: Note:
Note:Thediaphragmcanbereplacedwithoutremovingthevalvebody.
Step Step
Step1 1 1
OnlyuseAlaLavaldiaphragms.
Step Step
Step2 2 2
Actuatethevalvetothe”open“positionbyrotatingthehandwheelcounter-clockwiseuntilthevalveisullyopened.
Step Step
Step3 3 3
Removethebodyastenersbyusingacrosswisesequence.Removethebonnet.
Step Step
Step4 4 4
Actuatethevalvetothe”closed“positionbyrotatingthehandwheelclockwise.
Step Step
Step5 5 5
Removethediaphragmromthebonnet
Button Button
Button- - -style style stylecompr compr compressor: essor: essor:
-Removethediaphragmbypullingitoutslightly.
Thr Thr
Threaded eaded eaded- - -style style stylecompr compr compressor: essor: essor:
-Unthreadthediaphragminacounter-clockwisedirection.
Bayonet Bayonet
Bayonet- - -style style stylecompr compr compressor: essor: essor:
-Rotatethediaphragm90°andremove.
NOTE NOTE
NOTE
seeig.1-3,reverseactionostep9.
Step Step
Step6 6 6
Checkandcleanthreadandbayonetothecompressor.
Step Step
Step7 7 7
Ensure,thatthenewdiaphragmandthecontactareaonthevalvebodyarecleananddry.
10

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step8 8 8
Ensurethatthebonnetcompressormatchestheconnectionothediaphragm.Shouldthisnotbethecase,replacethe
compressor.
Step Step
Step9 9 9
Withthebonnetinthe"closed"position,installthediaphragmasollows:
Button Button
Button- - -style style stylecompr compr compressor: essor: essor:
-Insertdiaphragmwithapushandaslightrotation.
-Rotatethediaphragmuntiltheholesmatch.
Thr Thr
Threaded eaded eaded- - -style style stylecompr compr compressor: essor: essor:
-Threadthediaphragmintothecompressorinaclockwisedirection.Donotovertighten.
-Then,inecessary,turnthediaphragminacounter-clockwisedirectionuntiltheholesmatch.
Bayonet Bayonet
Bayonet- - -style style stylecompr compr compressor: essor: essor:
-Insertdiaphragmwithbayonetintothecompressorrecess.
-Rotatediaphragm90°.Holesmustmatch.
-Ensurediaphragmholderslotisalignedwithcompressorguides.
Fig.1Fig.2Fig.3
Step Step
Step10 10 10
Actuatethevalvetothe”open“position,seestep2.
Step Step
Step11 11 11
Alignthebonnettothevalvebodyusingbonnetasteners.Assemblethenutsand,inecessary,usewashers.Tosecurethe
bonnetandbody,tightentheastenersbyhand.
11

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step12 12 12
Actuatethevalvetoanalmostclosedposition.Fullyclosingthevalvecandamagethediaphragmposition,sothatthediaphragm
doesnotproperlyittotheweir,seestep4.Tightenthebodyastenerscross-wiseusingawrench.
NOTE! NOTE!
NOTE!Properassemblyextendsthelieothediaphragm.CorrectlyassembleddiaphragmshaveaCrescent-shapedbulgein
thediaphragmedgewhichcanbeobservedromtheside(Fig.6).
Fig.4Fig.5
Fig.6Size Size
SizeRec. Rec.
Rec.assembly assembly assemblytor tor torque que que
DN83-6Nm
DN1510-14Nm
DN2010-14Nm
DN2510-14Nm
DN4020-25Nm
DN5025-33Nm
DN6528-35Nm
DN80/10030-38Nm
Note: Note:
Note:Torquevaluesareguidance.Fig4tobeassessed
togetherwithtorquevalues.
Step Step
Step13 13 13
Actuatethevalvetothe”open“position,seestep2.Lightlyre-tightenthebodyastenerscross-wiseusingawrench.
NOTE NOTE
NOTE
Properassemblyextendsthelieothediaphragm.Correctlyassembleddiaphragmshaveacrescent-shapedbulgeinthe
diaphragmedgewhichcanbeobservedromtheside.
Step Step
Step14 14 14
Testthevalveorproperunction.
NOTE NOTE
NOTE
Checktheasteners24hoursateroperationothevalves.Incaseoleakageatthebody,depressurisethesystemand,i
necessary,tightentheastenersagainasdescribed.Ileakagecontinues,replacethediaphragm.Checkthetravelstopand
adjust,inecessary.
12

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
4.4Travelstopadjustment
Please Please
Pleasenote note note:
Section5.3isnot not
notvalidorsizesDN8andDN10(1/8"and3/8")
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
Beor Beor
Beore e eservicing servicing servicingany any anyinstalled installed installedvalve, valve, valve,you you youmust: must: must:
-depressurisethesystem
-openthevalve
-purgethevalve
Step Step
Step2 2 2
Makesurethatthebonnetanddiaphragmareproperlyinstalled.SeealsoReplacing Replacing
Replacingthe the thediaphragm diaphragm diaphragm.
Step Step
Step3 3 3
Rotatethehandwheelinaclockwisepositionuntilthevalveisullyclosed.
Step Step
Step4 4 4
Removetheplugromthetopothehandwheel,orcompositeversiononly.
Step Step
Step5 5 5
Unscrewcountersinkscrewbyallenkey.
13

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step6 6 6
Removescrew,handwheelandcoupling.
Step Step
Step7 7 7
Screwdownspindlebywrench,untilvalveisclosed..
Step Step
Step8 8 8
Usetwowrenchestoloosenthepositionnutandlocknut.
14

4Maintenance
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step9 9 9
Adjustthepositionopositionnut.
Step Step
Step10 10 10
Putcouplingon,andseethegapbetweenYokeandcouplingisadequate(~0.5mm).
Step Step
Step11 11 11
Holdpositionnutinplaceandcounterscrewlocknut.
Step Step
Step12 12 12
Remountcoupling,handwheelandtopscrew.
Tightenscrew.
Step Step
Step13 13 13
Testthevalveorproperunction.
Note: Note:
Note:Ithecompletelyclosedvalvedoesnotachievealeaktightseal,repeatsteps1to11,withslightlymoretightening
othestemasdescribedinstep7.
15

5Technicaldata
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
5.1Size
Size Size
SizeØD ØD ØDH H H
L L
L
(weld (weld
(weldends) ends) ends)
L L
L
(clamp) (clamp)
(clamp)
DN DN
DNInch Inch
Inchmm mm
mm(in) (in) (in)mm mm mm(in) (in) (in)mm mm mm(in) (in) (in)mm mm mm(in) (in) (in)
08-10¼"-⅜"Ø40(1.575)65(2.559)89(3.504)89(3.504)
15½"Ø62(2.441)101(3.976)110(4.331)108(4.252)
20¾"Ø62(2.441)116(4.567)119(4.685)118(4.646)
251"Ø87(3.425)128(5.039)129(5.079)127(5.000)
401½"Ø108(4.252)165(6.496)161(6.338)159(6.260)
502"Ø108(4.252)195(7.677)192(7.559)191(7.520)
652½"Ø172(6.772)255(10.039)218(8.58321D6(8.504)
803"Ø220(8.661)274(10.787)256(10.079)254(10.000)
1004"Ø220(8.661)280(11.024)218(8.583)305(11.961)
5.2Temperaturerecommendationsandservicelifetime
Diaphragm Diaphragm
Diaphragmpr pr properties operties operties- - -pr pr product oduct oductwetted wetted wettedar ar area ea ea
T T
Temperatur emperatur emperature e er r recommendations ecommendations ecommendations
Liquid Liquid
LiquidSteam Steam
Steam
Description Description
Description
Min. Min.
Min.Max. Max. Max.Max. Max. Max.
EPDM-40°C/-40°F130°C/266°F150°C/302°F1)
PTFE/EPDM-5°C/23°F175°C/347°F150°C/302°F2)
TFM/EPDM-5°C/23°F175°C/347°F150°C/302°F2)
1)Continuoustemperature
2)40min.steamsterilisation
Chemicalcompatibility:PleasecontactAlaLavalorinormation.
Diaphragm Diaphragm
Diaphragmservice service servicelietime lietime lietime
Diaphragm Diaphragm
Diaphragmmaterial material materialCode Code
Code
(marked (marked
(markedon on ondiaphragm) diaphragm) diaphragm)
Max. Max.
Max.r r recommended ecommended ecommendedservice service service
lietime lietime
lietimein in inyears years years
(stock (stock
(stockand and andoperation) operation) operation)
EPDMS2,S3,S48
PTFE/EPDM938
TFM/EPDMLC8
Note! Note!
Note!Correctstorage(e.g.inaccordancewithISO2230)isaprerequisiteorachievingthespeciiedstoragetime.
16

17

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Howto to tocontact contact contactAla Ala AlaLaval Laval Laval
Contactdetailsorallcountriesare
continuallyupdatedonourwebsite.
Pleasevisitwww.alalaval.comtoaccesstheinormationdirectly.
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