Alfalaval Unique Mixproof LP User manual

2314-0005
ESE02021-EN2 2016-07
Original manual
Instruction Manual
Unique Sanitary Mixproof LP and LP-F Valve

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 .............................................................................................. 7
3.1. Unpacking/intermediate storage ................................................................ 7
3.2. General information ............................................................................... 11
3.3. Welding ............................................................................................ 12
4. Operation ............................................................................................... 15
4.1. Operation .......................................................................................... 15
4.2. Troubleshooting and repair ...................................................................... 16
4.3. Recommended cleaning ......................................................................... 17
5. Maintenance ........................................................................................... 21
5.1. General maintenance ............................................................................. 21
5.2. Dismantling of valve .............................................................................. 25
5.3. Lower plug, replacement of radial seal ......................................................... 29
5.4. Upper plug, replacement of axial seal .......................................................... 31
5.5. Valve assembly .................................................................................... 33
5.6. Dismantling of actuator - 4” ...................................................................... 37
5.7. Assembly of actuator - 4” ........................................................................ 39
5.8. Dismantling of actuator - 6” ...................................................................... 41
5.9. Assembly of actuator - 6” ........................................................................ 43
6. Technical data ......................................................................................... 45
6.1. Technical data ..................................................................................... 45
7. Parts list and service kits ............................................................................ 47
7.1. Unique Mixproof LP Valve - wear parts 4" and 6" ............................................. 47
7.2. Unique Mixproof LP Valve - parts - 4” .......................................................... 50
7.3. Unique Mixproof LP Valve - parts - 6” .......................................................... 52
7.4. Unique Mixproof LP Valve - service kits - 4" and 6" ........................................... 54
7.5. Unique Mixproof LP-F Valve - wear parts 4" and 6" ........................................... 56
7.6. Unique Mixproof LP-F Valve - parts - 4” ........................................................ 58
7.7. Unique Mixproof LP-F Valve - parts - 6” ........................................................ 60
7.8. Unique Mixproof LP-F Valve - service kits - 4" and 6" ........................................ 62
3

1 EC 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 LP, Unique LP-F
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
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
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 summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Installation
Always read the technical data thoroughly.
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 stick your fingers through the valve ports if the actuator is supplied with compressed air.
Operation
Always read the technical data thoroughly.
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).
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.
Always fit the seals correctly (risk of mixing).
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 the warning label).
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.
2314-0006
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
2314-0007
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.
2314-0008
Step 5
Inspect the valve for visible transport damage.
Inspection!
2314-0009
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections, if supplied.
Caution!
2314-0009
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 7
Disassemble according to illustrations 1 to 6
(please also see 5.2 Dismantling of valve).
1. Supply compressed air.
2. Remove upper clamp.
3. Release compressed air.
4. Lift out actuator with plugs.
5. Remove lower clamp.
6. Take away lower sealing element.
on /off
2314-0010
1
2
5
4
3
6
9

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 8
Mount sealing element on valve.
2314-0011
Step 9
1. Place actuator part in the box.
2. Add supports.
3. Close box and store.
Advise!
Mark the valve body and box with the same number before
intermediate storage.
2314-0012
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.
3.2 General information
Step 1
Always read the technical data thoroughly.
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.
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
NOTE
Always install the valve vertically.
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 malfunction of the valve (leakage or faulty
indication).
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
2314-0013
!
Step 3
Fittings: Ensure that the connections are tight.
Remember seal rings!
2314-0014
Step 4
Air connection: R 1/8” (BSP).
1: Cleaning of upper seat.
2: Open valve.
3: Cleaning of lower seat.
2314-0015
AC1
AC2
AC3
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim for stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Cutting danger!
2314-0016
Step 2
Dismantle the valve in accordance with step 1, section 5.2
Dismantling of valve.
Step 3
NOTE
Maintain the minimum clearances 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 to leaving
a distance of 120 mm below the valve (look at the specific built-in
conditions).
B
C
A
2314-0017
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim for 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. Remove label after
installation of valve body
UP
Removelabel after
installationof valve body
UP
2314-0018
UP Remove label after
installation of valve body
Step 5
Assemble the valve in accordance with section 5.5 Valve assembly
after welding.
Pay special attention to the warnings!
Step 6
Pre-use check:
1. Supply compressed air to AC1, AC2 and AC3 one by one.
2. Operate the valve several times to ensure that it runs smoothly.
Pay special attention to the warnings!
Operate!
AC1
AC2
AC3
2314-0019
13

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim for stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
NOTE!
If ThinkTop® is mounted, add 180 mm to B measurement.
A. Lower sealing element can be removed without removing actuator and internal
valve parts.
B. Actuator and internal valve parts can be lifted out of the valve body.
B
C
A
2314-0017
Table 1. Dimensions - all measures in mm
4" 6”
Size LP LP-F LP LP-F
A 352 274 436 342
B 1201 1201 1193 1193
**C 123.6 123.6 172.7 172.7
NOTE!
**The measurement C can always be calculated by the formula
C=½ID-
upper +½ID- lower +1".
14

4Operation
The valve is adjusted and 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.
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!
2314-0020
15

4Operation
The valve is adjusted and 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.
4.2 Troubleshooting and repair
NOTE
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause/result Remedy
Leakage between sealing element (79)
and lower plug (75)
Worn/damaged O-rings/ lip seal
(76/77/78)
- Replace the O-rings/lip seal
- Change rubber grade
- Lubricate correctly
Leakage at the leakage outlet - 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 step 2, section
5.5 Valve assembly
Leakage at sealing element (48)/upper
plug (55)
Worn/product affected 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) - O-rings (76 and 47) too old/damaged
(and 52 if clamped valve body)
- Loose clamp (64)
- Replace the O-rings
- Change rubber grade
- Tighten the clamp
CIP leakage Worn O-rings (40/67/71) Replace the O-rings
Leakage at spindle clamp (43) Damaged O-ring (39) Worn/product
affected lip seal (57) or spray nozzle (58)
- Replace the O-ring
- Replace the plug seals
- Change rubber grade
Lowerplugnotreturningtoclosed
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
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= Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
4.3 Recommended cleaning
Step 1
Never touch the valve or the pipelines when sterilising.
Caustic danger!
Always use rubber gloves! Always use protective
goggles!
Step 2
Never touch the valve or the pipelines when sterilising. Burning danger!
2314-0020
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=Nitricacid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 3
Never throttle the leakage outlet.
Never throttle the CIP outlet, if supplied.
(Risk of mixing due to overpressure).
2314-0021
Leakage/CIP out
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC2. 0.5% by weight HNO3at 70oC
1kg
NaOH +100 l water =Cleaning agent. 0.7 l
53% HNO3+100 l water =Cleaning agent.
=
2.2 l
33%NaOH +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!
Step 6
Advisory seat lift cleaning periods:
Cleaning periods of 3-6 seconds per CIP sequence.
Product Periods
Milk 1-2
Yoghurt 3-5
Beer 2-5
Cold wort 5-10
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= Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 7
Always rinse well with clean water after cleaning. Always rinse!
Clean water Cleaning agents
Step 8
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
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=Nitricacid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Seat-cleaning cycles:
Pay special attention to the warnings!
1. Closed valve
A. Product
B. CIP
2314-0022
A
B
2. Cleaning through lower line
A. Product
B. CIP
2314-0023
A
B
3. Open valve
A. Product
2314-0024
A
4. Cleaning through upper line
A. Product
B. CIP
2314-0025
B
A
20