Alfalaval Unique Mixproof User manual

TD 449-006_1
ESE00923-EN11 2020-01
Original manual
Instruction Manual
Unique Mixproof Valve (including US version)

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 ........................................................................... 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Safety precautions ................................................................................ 7
3. Installation .............................................................................................. 8
3.1. Unpacking/intermediate storage ................................................................ 8
3.2. General information ............................................................................... 10
3.3. Welding ............................................................................................ 12
3.4. Recycling information ............................................................................. 16
4. Operation ............................................................................................... 17
4.1. Operation .......................................................................................... 17
4.2. Fault finding and repair ........................................................................... 18
4.3. Recommended cleaning ......................................................................... 19
5. Maintenance ........................................................................................... 23
5.1. General maintenance ............................................................................. 23
5.2. Dismantling the valve ............................................................................. 25
5.3. Lower plug, replacement of radial seal ......................................................... 27
5.4. Upper plug, replacement of axial seal .......................................................... 29
5.5. Valve assembly .................................................................................... 31
5.6. Dismantling of actuator ........................................................................... 34
5.7. Assembly of actuator ............................................................................. 35
6. Technical data ......................................................................................... 36
6.1. Technical data ..................................................................................... 36
7. Parts list and service kits ............................................................................ 39
7.1. Four configurations examples ................................................................... 39
7.2. Actuator ............................................................................................ 41
7.3. Plug setup overview .............................................................................. 45
7.4. Plug setup 1 ....................................................................................... 49
7.5. Plug setup 2 ....................................................................................... 53
7.6. Plug setup 3 ....................................................................................... 57
7.7. Plug setup 4 ....................................................................................... 61
7.8. Plug setup 5 ....................................................................................... 65
7.9. Plug setup 6 ....................................................................................... 69
7.10.Plug setup 7 ....................................................................................... 73
7.11.Plug setup 8 ....................................................................................... 77
7.12.Plug setup 9 ....................................................................................... 81
7.13.Plug setup 10 ..................................................................................... 85
7.14.Plug setup 11 ..................................................................................... 89
7.15.Plug setup 12 ..................................................................................... 93
7.16.Plug setup 13 ..................................................................................... 97
7.17.Plug setup 14 ..................................................................................... 101
7.18.Plug setup 15 ..................................................................................... 105
7.19.Plug setup 16 ..................................................................................... 109
7.20.Valve body ......................................................................................... 113
3

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
7.21.Axial installation tool .............................................................................. 115
7.22.Radial installation tool ............................................................................ 117
4

1 Declaration of Conformity
Revision of Declaration of Conformity 2013-12-03
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 std.
Ty p e
Serial number: 1181354 to 9999999
Serial number from AAB000000001 to AAB999999999
Serial number from 100700000001 to 100799999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- The valve is in compliance with the Pressure Equipment Directive 2014/68/EC 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
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment
Lars Kruse Andersen
Title Name
Kolding 2020-01-23
Place Date Signature
5

2Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 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:
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 damage to the valve are avoided.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly (see chapter 6.1 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 6.1 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 sterilizing.
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 6.1 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)
Always useAlfaLavalgenuinespareparts. ThewarrantyofAlfaLavalproductsisdependentontheuseof
Alfa Laval genuine spare parts.
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 out of 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
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 normally 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.
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
Step 4
Remove possible packing materials from the valve ports.
TD 449-043_1
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 normally visible.
Step 5
Inspect the valve for visible transport damages.
TD 449-327
Inspection!
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections, if supplied.
TD 449-044_1
Caution!
Step 7
Disassemble according to illustrations 1 to 6 (please also see
section 5.2 Dismantling the 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.
A=on
B=off
C=air
TD 449-017_1
13
4
2
5
6
AB
C
Step 8
Mount sealing element on valve.
TD 449-023_1
9

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 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.
TD 449-024_1
3.2 General information
Step 1
Always read the technical data carefully.
See section 6.1 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 normally visible.
Alfa Laval cannot be held responsible for incorrect installation.
NOTE
Always install the valve vertically.
The leakage outlet must be turned downwards!
Step 2
Avoid stressing 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.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
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.
Step 3
Fittings: Ensure that the connections are tight.
Remember seal rings!
Step 4
Air connection: R 1/8” (BSP).
AC1: Cleaning of upper seat.
AC2: Open valve.
AC3: Cleaning of lower seat.
TD 449-047_1
AC3
AC2
AC1
Step 5
CIP connection (optional extra):
1. See description of cleaning in section 4.3 Recommended
cleaning.
2. Connect CIP correctly.
CIP in CIP in
R3/8”(BSP),
external thread
TD 449-048_1
CIP out
11

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 6
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.
3.3 Welding
Step 1
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air. Cutting danger!
Air
TD 449-325
Step 2
Dismantle the valve in accordance with Step 1 in section 5.2 Dismantling the valve.
Step 3
NOTE
Maintain the minimum clearances so that the actuator with the
internal valve parts can be removed - please see later this section!
If there is a risk of foot damage, Alfa Laval recommends to leave
adista
nce of 120 mm (4.7”) below the valve (look at the specific
built-in conditions).
A
C
B
TD 449-024_1
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.
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 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!
TD 449-045_2
AC3
AC2
AC1
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.
NOTE!
If ThinkTop® is mounted, add 180 mm (7,1”) to B measure.
Table 1 and 2
1. Lower sealing element can be removed without taking out
actuator and internal valve parts.
2. Actuator and internal valve parts can be lifted out of the
valve body.
A
C
B
TD 449-024_1
Table 1. (All measures in mm) (1 mm = 0.0394”)
ISO DIN
DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN
Size 38 51 63.5 76.1 101.6 40 50 65 80 100 125 150
A
Basic/SeatClean 160 200 250 250 290 160 200 240 220 280 320 305
PMO 195 225 245 279
A
HighClean/UltraClean 200 265 300 300 360 200 265 290 270 350 390 375
PMO 265 300 320 349
*C60.8 73.8 86.3 98.9 123.6 64 76 92 107 126 151 176
B
Basic 700 760 909 909 1148 700 760 909 909 1148 1350 1370
SeatClean 700 760 880 880 1050 700 760 880 880 1050 1250 1270
PMO 765 885 900 1050
B
HighClean/UltraClean 810 870 1020 1020 1250 810 870 1020 1020 1250 1400 1420
PMO 877 1047 1060 1250
*Them
easure C can always be calculated by the formula C = ½ ID upper + ½ ID lower + 26 mm (1”).
14

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.
NOTE!
If ThinkTop® is mounted, add 180 mm (7,1”) to B measure.
Table 3 a n d 4
1. Lower sealing element can only be dismantled if actuator
and internal parts are removed.
A
C
B
TD 449-024_1
Table 2 .
ISO DIN
DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN
Size 38 51 63.5 76.1 101.6 40 50 65 80 100 125 150
A
Basic/Seat Clean 120 140 170 170 200 120 140 170 160 200 250 235
PMO 135 145 165 189
A
HighClean/UltraClean 170 190 220 220 270 170 190 220 210 270 320 305
PMO 190 220 240 259
15

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 Recycling information
• 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
-Duringmainten
ance, oil and wearing parts in the machine are replaced
-Allmetalpart
s should be sent for material recycling
-Wornoutordef
ective electronic parts should be sent to a licensed handler for material recycling
-Oilandallno
n-metal wear parts must be disposed off in agreement with local regulations
• Scrapping
- At 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
16

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 carefully.
See section 6.1 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!
TD 449-326
17

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 Fault finding and repair
NOTE
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause/result Repair
Leakage between sealing element (79)
and lower plug (75)
Worn/product affected 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/product affected plug seal rings
(56/74)
- Plug not assembled correctly
-Removetheparticles
- Check the plug seals
- Replace the plug seals
- Change rubber grade
- Assemble plug, see step 3 section 5.5
Valve assembly
Leakage at sealing element (48)/upper
plug (55)
Worn/product affected o-rings/lip seal
(sizes 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) - Too old/product affected o-rings (76
and 47) (and 52 if clamped valve body)
- Loose clamp (64)
- Replace the o-rings
- Change rubber grade
-Tightentheclamp
CIP leakage Worn o-rings (40/67/71) Replace the o-rings
Leakage at spindle clamp (43) Damaged o-ring (39) W orn/product
affected lip seal (57) or spray nozzle (58)
- Replace the o-ring
- Replace the plug seals
- Change rubber grade
Lower 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
18

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.
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!
TD 449-326
Step 3
Never throttle the leakage outlet.
Never throttle the CIP outlet, if supplied.
(Risk of mixing due to overpressure).
CIP in CIP in
TD 449-056_1
TD449-330
Leakage/CIP out CIP out
19

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.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC (158°F) . 2. 0.5% by weight HNO3at 70oC(158
°F).
1kg(2.2lb)
NaOH +100l(26.4gal) water =Cleaning agent. 0.7 l (0.2 gal) 53% HNO3
+100 l (26.4 gal)
water =Cleaning
agent.
2.2 l (0.6 gal)
33%NaOH +100l(26.4gal) water =Cleaning agent.
Step 5
1. Avoid excessive concentration of the cleaning agent
=> Dose gradually!
2. Adjust the cleaning flow to the process.
Milk sterilization/viscous liquids
=> Increase the cleaning flow!
Step 6
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 21psi (1.5 bar) 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 3Energi
zed *0.5 sec3
Lower seat lift 2 Energized *0.5 sec 3
SpiralClean vent --
*0.5 sec 3
Warm pre-rinse @
3minutes OD cleaning --
*5 sec 2
Upper seat lift 3Ener
gized *0.5 sec 3
Lower seat lift 2 Energized *0.5 sec 3
SpiralClean vent --
*0.5 sec 3
Hot alkaline wash
@ 10 minutes OD cleaning --
*5 sec 2
Upper seat lift 3Ene
rgized *0.5sec 3
Lower seat lift 2 Energized *0.5 sec 3
SpiralClean vent --
*0.5sec 3
Cold post wash @
3minutes OD cleaning --
*5 sec 2
Upper seat lift 3En
ergized *0.5 sec 3
Lower seat lift 2 Energized *0.5 sec 3
SpiralClean vent --
*0.5 sec 3
Cold acidified 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.
20