Alfalaval Unique Mixproof 3-body User manual

2319-0171
100000711-EN1 2018-12
Original manual
Instruction Manual
Unique Mixproof 3-body

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Introduction ............................................................................................ 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/intermediate storage ................................................................ 7
3.2. Recycling .......................................................................................... 10
3.3. General installation ................................................................................ 11
3.4. Welding ............................................................................................ 13
4. Operation ............................................................................................... 15
4.1. Operation .......................................................................................... 15
4.2. Recommended cleaning ......................................................................... 15
4.3. Troubleshooting and repair ...................................................................... 21
5. Maintenance ........................................................................................... 22
5.1. General maintenance ............................................................................. 22
5.2. Dismantling of valve .............................................................................. 23
5.3. Lower plug, replacement of radial seals ........................................................ 26
5.4. Upper plug, replacement of axial seal .......................................................... 31
5.5. Assembly of valve ................................................................................. 33
5.6. Dismantling of actuator ........................................................................... 38
5.7. Assembly of actuator ............................................................................. 40
6. Technical data ......................................................................................... 42
6.1. Technical data ..................................................................................... 42
7. Parts list and service kits ............................................................................ 43
7.1. Introduction ........................................................................................ 43
7.2. Actuator ............................................................................................ 44
7.3. Plug setup overview .............................................................................. 46
7.4. Plug setup 23 ..................................................................................... 48
7.5. Plug setup 25 ..................................................................................... 50
7.6. Plug setup 31 ..................................................................................... 52
7.7. Plug setup 33 ..................................................................................... 54
7.8. Plug setup 37 ..................................................................................... 56
7.9. Plug setup 39 ..................................................................................... 58
7.10.Valve bodies ....................................................................................... 60
7.11.Installation kit B ................................................................................... 62
7.12.Installation kit C ................................................................................... 64
7.13.Installation kit G ................................................................................... 66
7.14.Installation kit H + B .............................................................................. 68
7.15.Axial installation tool .............................................................................. 70
7.16.Radial installation tool ............................................................................ 72
3

1Introduction
Thank you for purchasing an Alfa Laval product.
This manual has been provided to instruct you in how to operate and service this product correctly and safely. Make sure that
you follow all directions and instructions; failure to do so could result in personal injury or equipment damage.
This manual should be considered part of this product and should remain with it at all times for reference. (If you sell it, please be
sure to include this manual with it.) Warranty is provided as part of Alfa Laval’s commitment to our customers who operate and
maintain their equipment as this manual dictates. Failure to do so may result in loss of warranty.
Where defects appear on the product during the warranty period, Alfa Laval will take back the product and correct the problem.
Should the equipment be modified or not kept in the manner prescribed within this manual, the warranty will become null and void.
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.1 Important information
Important information
Always read the manual before using the valve!
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: Cutting danger:
5

2Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly (see section 6 Technical data) !
Always release compressed air after use
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Operation:
Always read the technical data thoroughly (see section 6 Technical data)
Never touch the clip assembly or the actuator piston rod when the actuator is supplied with compressed
air (see warning label) !
Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing)
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never throttle the leakage outlet
Never throttle the CIP outlet, if supplied
Always handle lye and acid with great care
Maintenance:
Always read the technical data thoroughly (see section 6 Technical data) !
Always fit the seals correctly
Always release compressed air after use
Always remove the CIP connections, if supplied, before service.
Never service the valve when it is hot
Never pressurise the valve/actuator when the valve is serviced
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never service the valve with valve and pipelines under pressure
Transportation:
Always ensure that compressed air are released
Always ensure that all connections is disconnected before attempting to remove the valve from the installation
Always drain liquid from valves before transportation
Always used predesigned lifting points if defined
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available, it
must be used
6

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
3.1 Unpacking/intermediate storage
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve
2. Delivery note
3. Warning label
Step 2
Remove upper support
2319-0172
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
2319-00173
7

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
Step 4
Remove possible packing materials from the valve ports.
2319-0174
Step 5
Inspect the valve for visible transport damage.
2319-0175
8

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections.
2319-0176
Step 7
Disassemble according to illustrations
(please also see 5.2 Dismantling of valve).
1. Supply compressed air.
2. Remove upper clamp (64).
3. Release compressed air.
4. Lift out actuator with plugs. Compressed
air supply
2319-0160
64
50
64
64
149
9

3 Installation
Step 8
While valve body is welded, it is recommended to store the valve
safely in the box together with valve parts.
1. Place actuator and valve parts in the box.
2. Add supports.
3. Close, re-tape and store the box.
ADVICE!
Mark the valve body and box with the same number before
intermediate storage.
2319-0037
3.2 Recycling
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
-Woodandca
rdboard boxes can be re-used, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
-Metalstr
aps should be sent for material recycling.
Maintenance
- During maintenance, oil and wearing 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 disposed off in accordance with local regulations
Scrapping
- At the end of use, the equipment must be recycled according to the relevant, local regulations. Besides 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 your local Alfa Laval sales company
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
3.3 General installation
Step 1
- Always read the technical data thoroughly (see section 6 Technical data).
- Always release compressed air after use.
- Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see the warning label)
CAUTION!
- Fit the supplied warning label on the valve so that it is clearly visible.
- Alfa Laval cannot be held responsible for incorrect installation
NOTE!
- Mount valves vertically, or as close to vertical as possible having the leakage outlet turned downwards.
Step 2
Avoid stresses to the valve as this can result in deformation of
the sealing area and misfunction of the valve (leakage or faulty
indication).
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes (especially at long tube lengths)
- Excessive welding
- Overloading of the pipelines
NOTE!
Please follow Alfa Laval installation guidelines
(literature code ESE00040).
2319-0177
!!
Step 3
Fittings
Ensure that the connections are tight.
Remember seal
rings!
2319-0178
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
Step 4
1
2
3
B
A
C
D
2319-0099
A=Airout1A
B=Airin
C=Airout3
D=Airout2
Valve Pneumatic Connections
ThinkTop
Fitting ID
Actuator
Fitting ID
Out 1A Air connection 2
Out 2 Air connection 3
Out 3 Air connection 1
Air connection: R 1/8” (BSP).
2319-0179
AC1
AC2
AC3
AC1 = Air connection 1 upper seat push
AC2 = Air connection 2 open/close
AC3 = Airconnection3lowerseatpush
Step 5
It is important to connect CIP inlet to the small inlet nozzle to avoid
built-up pressure in the cleaning chamber.
CIP in CIP out
TD 449-127
Align nozzle edges with recess in sealing element.
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.4 Welding
Step 1
Never stick your fingers in the operating parts of the valve if the
actuator is supplied with compressed air.
2319-0180
!
Step 2
Dismantle the valve in accordance with the description of dismantling the valve, see 5.2 Dismantling of valve
Step 3
Before welding the valve into the pipe line please note:
1. Maintain the minimum clearances "A" so that the actuator with
the internal valve parts can be removed - please see later on
in this section!
If there is a risk of foot damage, Alfa Laval recommends leaving
a distance of 120 mm (4.7”) below the valve (look at the specific
built-in conditions).
ISO DIN
Size DN/OD
51
DN/OD
63.5
DN/OD
76.1
DN/OD
101.6
DN
50
DN
65
DN
80
DN
100
A 265 300 300 360 265 290 270 350
B* 835 970 980 1175 835 970 980 1175
C73.8 86.3 96.9 123.6 76 92 107 126
NOTE! If ThinkTop® is mounted, add 180 mm (7,1") to B measure.
(All measures in mm) (1 mm = 0.0394”)
AB
CC
2319-0161
Remove label after
installation of valve body
UP
13

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 4
WARNING
Make sure to turn the valve body correctly - conical valve seat
upwards.
TD 449-329
UP
Remove label after
installation of valve body
Step 5
Assemble the valve in accordance with section 5.5 Assembly of valve after welding.
Pay special attention to the warnings and clamp torque (see section 5.5 Assembly of valve).
Step 6
Pre-use check:
1. Supply compressed air to air connection 1, 2 and 3 one by one.
2. Operate the valve several times to ensure that it runs smoothly.
Pay special attention to the warnings!
AC1 = Air connection 1 upper seat push
AC2 = Air connection 2 open/close
AC3 = Air connection 3 lower seat push
2319-0181
AC1
AC2
AC3
14

4Operation
The valve is tested before delivery.
Study the instructions carefully and pay special attention to the warnings!
Pay attention to possible faults.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
-Always read the technical data thoroughly (see section 6 Technical data).
-Always release compressed air after use.
-Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air (see the warning label).
-Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing).
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.
4.2 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
15

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3= Nitric acid.
Step 2
Never touch the valve or the pipelines when sterilising.
Step 3
- Never throttle the leakage outlet
- Never throttle the CIP outlet, if supplied.
(Risk of mixing due to overpressure).
A= CIP in
B= CIP out
Step 4
1. Avoid excessive concentration of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the process
Milk sterilisation/viscous liquids
⇒Increase the cleaning flow!
16

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3=Nitricacid.
Step 5
Recommended cleaning - general
Each mixproof valve shall be properly operated, including seat lifting, during CIP cleaning to assure exposure to product
contact surfaces.
Alfa Laval offers the option of cleaning the leakage chamber by utilizing the SpiralClean nozzle during the CIP Cleaning.
The SpiralClean nozzle is accessed through the external inlet located at the Intermediate piece.
The CIP through the SpiralClean nozzle can be controlled by an external valve. Minimum recommended CIP pressure 2
bar (29 psi).
Alfa Laval offers the option of cleaning the OD of the upper and lower valve plug shaft(s) by utilizing the CIP sealing elements.
The CIP of the valve shaft(s) has an external inlet and outlet positioned on the sealing elements. Minimum recommended
CIP pressure 2 bar (29 psi).
The CIP through the SpiralClean nozzle can be controlled by an external valve(s).
Alfa Laval recommends that OD cleaning of the valve plug shafts is only performed during CIP of the valve. For example: If
onlytheupperportionofthevalvebodyiscleanedwhilethere is product present in the lower portion of the valve body.
OD cleaning should only be performed on the upper plug.
Step 6
Recommended cleaning - specific
The chart below provides reference to cleaning solution agents, temperature and exposure times necessary during circulation
to achieve good cleaning results.
All data shown is required for each valve during cleaning. Use clean water, free from chlorides, for mixing with chemical
cleaning agents.
CIP event Exposure time Temperature Agent Concentration
Warm pre-rinse 3 minutes continuous 38-43 °C (100 – 110 °F) None None
Hot alkaline wash 10 minutes continuous 71 °C (160 °F) NaOH (Sodium hydroxide) 1%
Cold post wash 3 minutes continuous Cold None None
Cold acidified rinse 3 minutes continuous Cold EHNO3(Nitric acid) 0.006%
17

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3= Nitric acid.
Step 7
Valve pneumatic operation during in-place cleaning
Each valve seat shall be lifted during the length of the cleaning cycle.
Seat lift durations shall not exceed 10 seconds.
These pneumatic functions include:
1. Upper valve seat lift (takes place during cleaning of upper valve body)
2. Lower valve seat push (takes place during cleaning of lower valve body)
The following chart presents an overview of these functions together with the recommended time durations at 1.5 bar (21psi) CIP
pressure. It is recommended to do seat lift/push in the middle of each step in the CIP sequence.
CIP event @ length Valve function Valve
solenoid no.
Solenoid
mode
Actual opening
time
Number of lifts/push
in each CIP step
Upper seat lift 3Energized *0.5 sec 1
Lower seat lift 2 Energized *0.5 sec 1
SpiralClean vent - - *5 sec 3
Warm pre-rinse @
3minutes
OD cleaning --
*5 sec 2
Upper seat lift 3Energized *0.5 sec 2
Lower seat lift 2 Energized *0.5 sec 2
SpiralClean vent - - *5 sec 3
Hot alkaline wash
@ 10 minutes
OD cleaning --
*5 sec 2
Upper seat lift 3Energized *0.5 sec 1
Lower seat lift 2 Energized *0.5 sec 1
SpiralClean vent - - *5 sec 3
Cold post wash @
3minutes
OD cleaning --
*5 sec 2
Upper seat lift 3Energized *0.5 sec 1
Lower seat lift 2 Energized *0.5 sec 1
SpiralClean vent - - *5 sec 3
Cold acidified rinse
@3minutes
OD cleaning --
*5 sec 2
Upper seat lift 3Energized *0.5 sec 1
Lower seat lift 2 Energized *0.5 sec 1
SpiralClean vent - - *5 sec 3
Final rinse @
3minutes
OD cleaning --
*5 sec 2
*Time stated is the actual opening time for the valve. Programmed duration is depended on the access to compressed air and response
time from PLC.
Variations caused by compressed air are typically:
- Long compressed air supply hoses.
- Small ID on air supply hoses.
- Limited availability of compressed air.
- Some products may require additional number of seat lifts/pushes.
- Duration of seat lift/push depend on available CIP pressure.
18

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3=Nitricacid.
Step 8
Consumption cleaning fluids
The table below approximates the flow of cleaning solution through the valve vent tube during seat lift functions, SpiralClean of
ventandCIPofODvalveplugshaftsataCIPpressureof1.5bar(21psi).
Valve size
DN/OD / DN
Seat lift
seat push KV(m3/h) Litre pr. min.
(1.5 bar/ 21psi) Duration Activations during
each CIP event
Seat lift 1.8 2.69
51/DN50 Seat push 1.3 1.83 0.5 sec 3
Seat lift 2.4 3.38
63.-76.1 / DN65-80 Seat push 2.1 2.95 0.5 sec 3
Seat lift 3.4 4.76
101.6 / DN100 Seat push 2.6 3.67 0.5 sec 3
SpiralClean 51-101.6 /
DN50-100 -0.14 0.16 0.5 sec 3
CIP OD valve plug 51-63.5 /
DN50-65 -0.29 0.32 5sec 2
CIP OD valve plug 76.1-101.6
/ DN80-100 -0.34 0.40 5sec 2
Formula to estimate CIP flow during seat lift (for liquids with comparable viscosity and density to water)
Q=CIP-flow(m
3/h).
KVvaluefromthetableabove.
∆p = CIP pressure (bar).
Assumption: density = 1
Step 9
Guide rings cleaning
When the valves are removed for replacement of wetted parts and / or sealing elastomers, it is important to remove, and hand
clean, the PTFE guide rings (positions 45, 54, 80 and 98) and their seating groves before placing the valves back into service.
See section 5.5 Assembly of valve
Step 10
Always rinse well with clean water after cleaning.
NOTE!
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agents
19

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda.
HNO3= Nitric acid.
Step 11
Seat-cleaning cycles:
Pay special attention to the warnings!
1. Closed valve
2319-0213
2. Open valve
2319-0214
3. Cleaning through upper line
2319-0215
4. Cleaning through lower line
2319-0216
20