Alfalaval Unique Mixproof Horizontal Tank User manual

2317-0010
ESE02424-EN2 2016-07
Original manual
Instruction Manual
Unique Mixproof Horizontal Tank Valve - sizes 2½”, 3”, 4” and 6”
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Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Declaration of conformity ............................................................................ 4
2. Introduction ............................................................................................ 5
3. Safety .................................................................................................... 6
3.1. Important information ............................................................................. 6
3.2. Warning signs ..................................................................................... 6
3.3. Safety precautions ................................................................................ 7
4. Installation .............................................................................................. 8
4.1. Unpacking/intermediate storage ................................................................ 8
4.2. Recycling .......................................................................................... 10
4.3. General installation ................................................................................ 11
4.4. Welding ............................................................................................ 12
5. Operation ............................................................................................... 15
5.1. Operation .......................................................................................... 15
5.2. Troubleshooting and repair ...................................................................... 16
5.3. Recommended cleaning ......................................................................... 17
6. Maintenance ........................................................................................... 19
6.1. General maintenance ............................................................................. 19
6.2. Dismantling of valve (excluding actuator) ....................................................... 22
6.3. Replacement of seal ring, tank plug ............................................................ 26
6.4. Replacement of seal ring, balanced plug ....................................................... 28
6.5. Valve reassembly (excluding actuator) .......................................................... 30
6.6. Dismantling of actuator ........................................................................... 42
6.7. Actuator re-assembly ............................................................................. 45
7. Technical data ......................................................................................... 46
7.1. Technical data ..................................................................................... 46
8. Parts list ................................................................................................ 49
8.1. Wear parts ......................................................................................... 49
8.2. Parts ............................................................................................... 51
8.3. Service kits ........................................................................................ 53
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1 Declaration of conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique HT
Type
From serial number 1181354 - 9999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
- The valve is in compliance with the Pressure Equipment Directive 2014/68/EU and was subjected to the following
assessment procedure Module A. Diameters ≥DN125 may not be used for fluids group 1.
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 2013-03-07
Place Date Signature
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2 Introduction
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 Inc. 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.
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3 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
3.1 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.
3.2 Warning signs
General warning: Caustic agents: Cutting danger:
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3 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
3.3 Safety precautions
Installation:
Always read the technical data thoroughly (see chapter 7.1 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 chapter 7.1 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 chapter 7.1 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
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4 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.
4.1 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
2317-0011
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
2317-0012
Step 4
Remove possible packing materials from the valve ports.
2317-0013
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4 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 5
Inspect the valve for visible transport damage.
2317-0014
Inspection!
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections.
2317-0015
Caution!
Step 7
Disassemble according to illustrations 1 to 4
(please also see 6.2 Dismantling of valve (excluding actuator)).
1. Supply compressed air.
2. Remove clamp
3. Release compressed air.
4. Lift out actuator with plugs.
2317-0016
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.
2317-0017
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4 Installation
4.2 Recycling
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, 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 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
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4 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.
4.3 General installation
Step 1
- Always read the technical data thoroughly (see 7.1 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!
- The leakage outlet must be 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).
Risk of damage!
2317-0018
!
Step 3
Fittings
Ensure that the connections are tight.
Remember seal rings!
2317-0019
Step 4
Valve Pneumatic Connections
ThinkTop
Fitting ID
Actuator
Fitting ID
Out 1A Air connection 2 (blue)
Out 2 Air connection 3 (yellow)
Out 3 Air connection 1 (red)
Air connection: R 1/8” (BSP).
2317-0020
AC1 AC2 AC3
AC1 = Air connection 1 (red) upper seat push
AC2 = Air connection 2 (blue) open/close
AC3 = Air connection 3 (yellow) lower seat push
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4 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
4.4 Welding
Step 1
Never stick your fingers in the operating parts of the valve if the
actuator is supplied with compressed air.
Cutting danger!
2317-0021
Air
Step 2
Dismantle the valve in accordance with the description of
dismantling the valve, see 6.2 Dismantling of valve (excluding
actuator)
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4 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 3
Before welding the flange into the tank 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 below the valve (look at the specific
built-in conditions).
Dimension (all measures in mm).
LS
P
A
A*
G
E
N
K
J
H
15˚
OD
V ˚
Q
B
2317-0001
t
ID
øD
X
Z
Y
M
Size 2.5" 3" 4" 6"
(75 mm) stroke
6"
(59 mm) stroke
A 735 759 977 1088 1088
A* 867 904 1155 1329 1329
B 220 220 300 420 420
OD 63.5 76.1 101.6 154.2 154.2
ID 60.3 72.9 97.6 146.86 146.86
t 1.60 1.60 2.00 3.67 3.67
øD 186 186 186 186 186
E 70.9 77.2 92.2 129.5 129.5
F1 38 38 75 75 59
F2 (Tank plug) 10 10 10 10 10
G 15.9 15.9 38.1 44.5 44.5
H 281 291 364 423 423
J 246 252 317 359 359
K 153 158 215 307 307
L 252 252 379 379 379
N 152 170 210 283 283
P 89.3 101.9 126.6 180 180
Q 15.9 15.9 38.1 44.5 44.5
S 180 180 180 180 180
V° 0-67° 0-60° 0-53° 0-49° 0-53°
X 38.3 36.6 52.6 93.8 96.8
Y3/4” clamp ferrule 3/4” clamp ferrule 3/4” clamp ferrule 3/4” clamp ferrule 3/4” clamp ferrule
Z 4” 4” 6” 10” 10”
M/Tri-clamp 21 21 21 38.56 38.56
Weight (kg) 13.0 14.2 43.1 87.6 87.6
Step 4
Assemble the valve in accordance with section 6.5 after welding.
Pay special attention to the warnings and clamp torque (see
section 6.5).
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4 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 5
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 (red) upper seat push
AC2 = Air connection 2 (blue) open/close
AC3 = Air connection 3 (yellow) lower seat push
2317-0020
AC1 AC2 AC3
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5Operation
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.
5.1 Operation
Step 1
-Always read the technical data thoroughly (see chapter 7.1 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.
Burning danger!
2317-0022
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5Operation
Study the maintenance instructions carefully before replacing worn parts. - See “General Maintenance” section 4.1
5.2 Troubleshooting and repair
Problem Cause/result Remedy
Leakage at the vent port body (106) - Particles between valve seats and plug
seals (56/74)
- Worn/damaged plug seal rings (56/74)
- Plug not assembled correctly
- Remove the particles
- Check the plug seals
- Replace the plug seals
- Change rubber grade
- Assemble plug, see section 6.5
Leakage at sealing element (110)/
balanced plug (94)
Worn/damaged O-rings/lip seal
(38/39/46/49)
- Replace the O-rings/lip seal
- Change rubber grade
- Clean and if necessary replace guide
ring (45)
Leakage at clamp (64) and (65)
Leakage at spindle clamp (42)
- O-rings (76 and 47) and valve body
too old/damaged
- Loose clamp (64) or (65)
- Replace the O-rings
- Change rubber grade
- Tighten the clamp (max. 10 Nm)
CIP leakage Worn O-rings (40/67)
Damaged O-ring (39)
Worn/damaged lip seal (57)
Replace the O-rings
- Replace the O-ring
- Replace the plug seals
- Change rubber grade
Tank plug not returning to closed position - Wrong rubber grade
- Wrongly fitted gasket
- Mounted incorrectly (see section 2.3)
- Change rubber grade
- Fit new gasket correctly
- Correct installation
Plug returns with uneven movements
(slip/stick effect)
- Wrong rubber grade
- Wrongly fitted gasket
- Mounted incorrectly (see section 2.3)
- Change rubber grade
- Fit new gasket correctly
- Correct installation
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5Operation
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.
5.3 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!
2317-0022
Step 3
- Never throttle the leakage outlet
- Never throttle the CIP outlet, if supplied.
(Risk of mixing due to overpressure).
2317-0023
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC
1kgNaOH + 100 l water = Cleaning agent.
2.2 l
33% NaOH +100 l
water = Cleaning agent.
2. 0.5% by weight HNO3at 70oC
0.7 l
53% HNO3+100 l
water =Cleaning agent.
Step 5
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!
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5Operation
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 6
Advisory seat lift cleaning periods
Cleaning periods of 1-2 seconds per CIP sequence.
Product Periods
Milk 1-2
Yoghurt 3-5
Beer 2-5
Cold wort 5-10
Step 7
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
Step 8
1. Closed valve
A. = Product
B. = CIP
2317-0024
A
B
Step 9
2. Seat lift cleaning with tank plug (optional)
A. = Product
B. = CIP
C. = CIP out
2317-0025
A
B
C
Step 10
3. Open valve
A. = Product
B. = Leakage dection
2317-0026 B
A
Step 11
4. Seat lift cleaning with balanced plug
A. = Product
B. = CIP
C. = CIP out
2317-0027
A
B
C
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6 Maintenance
Maintain the valve/actuator regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and guide rings in stock. Store seals in closed bag.
The items refer to the parts list and service kits section.
6.1 General maintenance
Step 1
-Always read the technical data thoroughly (see 7.1 Technical data).
-Always fit the seals correctly (risk of mixing).
-Always release the compressed air after use.
-Always remove the CIP connections, if supplied, before service.
Replace all product wetted seals every 12 months.
NOTE!
All scrap must be stored/disposed of in accordance with current regulations/directives.
Step 2
-Never service the valve when it is hot.
-Never service the valve with valve/actuator under pressure
-Never service the valve with fluid in the tank.
Burning danger!
2317-0022
Atmospheric pressure required!
Step 3
Never stick your fingers in operating parts of the valve if the
actuator is supplied with compressed air.
Cutting danger!
2317-0021
Step 4
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air (see the warning label).
Moving parts!
2317-0028
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6 Maintenance
Maintain the valve/actuator regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and guide rings in stock. Store seals in closed bag.
The items refer to the parts list and service kits section.
Recommended spare parts: Service kits (see chapter 8)
Order service kits from the service kits section (see chapter 8)
Ordering spare parts: Contact the Sales Department.
Valve rubber seals Valve plug seals Valve guide rings
Preventive maintenance Replace after 12 months(*) Replace after 12 months(*) Replace when required
Maintenance after leakage
(leakage normally starts slowly)
Replace after production
cycle
Replace after production
cycle
Planned maintenance - Regular inspection for
leakage and smooth
operation
- Keep a record of the valve
- Use the statistics for
inspection planning
- Regular inspection for
leakage and smooth
operation
- Keep a record of the valve
- Use the statistics for
inspection planning
Replace when required
Lubrication When assembling
Klüber Paraliq or similar
USDA H1 GTE 703 approved
oil/grease (**) (suitable for
EPDM).
When assembling
Klüber Paraliq or similar
USDA H1 GTE 703 approved
oil/grease (**) (suitable for
EPDM).
None
NOTE!
Lubricate thread in valve plug parts with Klüber Paste UH1 84-201 or similar.
(*) Depending on working conditions! Please contact Alfa Laval.
(**) All products wetted seals.
Repairing of actuator:
- The actuator is maintenance-free but repairable.
- If repair is required, replacing all actuator rubber seals is recommended.
- Lubricate seals with Klüberplex BE31.
- To avoid possible black marks on pos. 1 and 29, Alfa Laval recommends Klüber Paraliq GTE703 (white) for these two
positions.
Operate!
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 operates
smoothly.
Pay special attention to the warnings!
1 = air connection 1 (AC1)
2 = air connection 2 (AC2)
3 = air connection 3 (AC3)
2317-0029
3
2
1
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