Alfalaval Unique RV-P User manual

2405-0001
ESE02801-EN2 2016-10
Original manual
Instruction Manual
Unique RV-P, pneumatic regulating 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/delivery ............................................................................... 7
3.2. General installation ................................................................................ 8
3.3. Welding ............................................................................................ 10
3.4. Recycling information ............................................................................. 13
4. Operation ............................................................................................... 14
4.1. Operation .......................................................................................... 14
4.2. Troubleshooting ................................................................................... 16
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling the valve ............................................................................. 20
5.3. Plug seal replacement ............................................................................ 22
5.4. Valve assembly .................................................................................... 22
6. Technical data ......................................................................................... 23
6.1. Technical data ..................................................................................... 23
7. Parts list and service kits ............................................................................ 25
7.1. Standard model ................................................................................... 25
7.2. Aseptic model ..................................................................................... 28
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity: 2016-06-01
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declares that
Valve
Designation
Unique RV-P, Unique RV-P-A
Type
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
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 2016-10-26
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
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:
5

2Safety
All warnings in this manual are summarised on this page.
Pay special attention to this 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 Technical data) !
Always release compressed air after use
Never touch moving parts if the actuator is supplied with compressed air
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never dismantle the valve with valve and pipelines under pressure
Never dismantle the valve when it is hot
Operation:
Never dismantle the valve with valve and pipelines under pressure !
Never dismantlethevalvewhenitishot
Always read the technical data thoroughly (see chapter 6 Technical data)
Always release compressed air after use
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never touch moving parts if the actuator is supplied with compressed air
Always rinse well with clean water after cleaning
Always handle lye and acid with great care
Maintenance:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Always release compressed air after use
Never service the valve when it is hot
Never service the valve with valve and pipelines under pressure
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch moving parts if the actuator is supplied with compressed air
Always useAlfaLavalgenuinespareparts.ThewarrantyofAlfa Laval products is dependent on the use of Alfa
Laval genuine spare parts.
Transportation:
Always ensure that compressed air is released
Always ensure that all connections are disconnected before attempting to remove the valve from the installation
Always drain liquid from valves before transportation
Always use 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
This instruction manual is part of the delivery. Study the instructions carefully.
The items refer to the parts list and service kits section.
The valve is assembled before delivery.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve
2. Delivery note
3. Instruction manual
Step 2
Remove possible packing materials from the valve/valve parts.
2405-0002
Step 3
Inspect the valve for visible transport damage.
2405-0003
7

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
Step 4
Avoid damaging the air connection, the electrical connection and
the valve ports.
2405-0004
!
!
!
3.2 General installation
Step 1
!
Always read the technical data thoroughly.
See chapter 6 Technical data.
!
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
Step 2
!
Never touch moving parts if the actuator is supplied with
compressed air.
Moving parts!
2405-0005
!
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
Step 3
To avoid water hammer, it is recommended to install the valve so
that the flow is against the closing direction.
Shock in the actuator must never occur.
Avoid water hammer!
Outlet
2405-0006
Inlet
Step 4
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
2405-0007
!
9

3 Installation
Study the instructions carefully.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
Always weld the valve body into the system when it is
disassembled fromthevalve.
Maintain the minimum clearance (A) so that the actuator can be
removed.
Valve size A(mm)
38 mm/DN40 100
51 mm/DN50 105
63.5 mm/DN65 130
76 mm/DN80 145
101.6 mm/DN100 180
2405-0008
A
10

3 Installation
Study the instructions carefully.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
Step 2
Assemble the valve in accordance with the steps on page 22.
Pay special attention to the warnings!
Standard model
1. Lubricate O-ring (21) and lip seal (25) with Klüber Paraliq GTE 703.
2. Fit seat (63) and O-ring (21) in the valve body (26).
3. Fit and tighten lower clamp (19).
4. Fit O-ring (21) and plug (23) in valve body (26).
5. Fit bushing (24) and lip seal (25) in the bonnet (112).
6. Mount the actuator (110) and bonnet (112) together with
thevalvepartsinthevalvebody(26).
7. Fit and tighten upper clamp (19).
8. Fit and tighten valve plug adjuster (114) and nut (115)
to the plug (23).
9. Fit and tighten the clamp fittings (111).
110
23
21
25
24
63
26
21
115
114
19
112
111
19
2405-0009_1
11

3 Installation
Study the instructions carefully.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
Aseptic model
1. Lubricate O-ring (21) with Klüber Paraliq GTE 703.
2. Fit seat (63) and O-ring (21) in the valve body (26).
3. Fit and tighten lower clamp (19).
4. Fit plug (23) in valve body (26).
5. Fit bushing (24) in the bonnet (112).
6. Mount the actuator (110) and bonnet (112) together with
the valve parts in the valve body (26).
7. Fit and tighten upper clamp (19).
8. Fit and tighten valve plug adjuster (114) and nut (115)
to the plug (23).
9. Fit and tighten the clamp fittings (111).
23
63
26
21
19
110
24
115
114
19
112
111
2405-0021_1
12

3 Installation
Study the instructions carefully.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
Step 3
Pre-use check:
1. Activate the valve using compressed air.
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings!
2405-0010
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
- 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 in accordance 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 liquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,or
in the absence of local regulations, please contact your local Alfa Laval sales company
13

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
!
Always read the technical data thoroughly.
See chapter 6 Technical data.
!
Always release compressed air after use.
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. Danger of burns!
2405-0011
!
Step 3
!
Never touch moving parts if the actuator is supplied with
compressed air.
Moving
parts!
2405-0005
!
14

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
Step 4
Lubrication of valves:
1. Ensure smooth movement between lip seal (25) and
plug stem (23).
2. Lubricate with Klüber Paraliq GTE 703 if necessary
(see section 5.1 General maintenance).
25
23
2405-0012
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
2405-0013
15

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section.
4.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts - section 5.1 General maintenance.
Problem Cause/result Repair
External product leakage Worn or damaged lip
seal and/or O-ring
- Replace the seals
- Replace with seals of a
different rubber grade
Internal product leakage - Worn or product-affected
plug seal - Replace the seal - Replace with a seal of a
different rubber grade
- Product deposits on
the seat and/or plug - Frequent cleaning
Water hammer The flow direction is the
same as the closing direction
-Theflowdirec
tion should be
against the closing direction
-Throttleair
release of solenoid in
top unit
4.3 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. Danger of burns!
2405-0011
!
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 3
Clean the plug and the seats correctly.
Pay special attention to the warnings
Lift and lower valve plug momentarily!
2405-0014
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC2.0.5%byweightHNO
3at 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.
2. Adjust the cleaning flow to the process.
3. 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
17

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock. Always use Alfa Laval genuine spare parts.
Check the valve for smooth operation after service.
5.1 General maintenance
Step 1
!
Always read the technical data thoroughly.
See chapter 6 Technical data
!
Always release compressed air after use.
NOTE
All scrap must be stored/discharged in accordance
with current regulations/directives.
Step 2
!
Never service the valve when it is hot.
!
Never service the valve with valve and pipelines under pressure.
2405-0015
!
Danger of burns!
Step 3
!
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Danger of cuts!
2405-0016
!
18

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and lip seals in stock. Always use Alfa Laval genuine spare parts.
Check the valve for smooth operation after service.
Step 4
!
Never touch the moving parts if the actuator is supplied with
compressed air.
Moving parts!
2405-0005
!
Below are some guidelines for maintenance and lubrication intervals.
Please note that the guidelines are for normal working conditions in one shift.
Product wetted seals
Preventive maintenance Replace after 12 months depending on working conditions
Maintenance after leakage (leakage normally starts slowly) Replace at the end of the day
Planned maintenance
- Regular inspection for leakage and smooth operation
- Keep a record of the valve
- Use the statistics for inspection planning
Replace after leakage
Lubrication
Before fitting
Klüber Paraliq GTE 703 or similar USDA H1 approved
oil/grease
Pre-use check:
1. Supply compressed air to the actuator.
2. Activate the positioner program P15 to initialise the positioner.
Pay special attention to the warnings!
2405-0017
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
5.2 Dismantling the valve
Step 1
Standard model
1. Loosen and remove upper clamp (19).
2. Unscrew the clamp fitting (111).
3. Unscrew the valve plug adjuster (114) and nut (115)
4. Lift away the actuator (110) and bonnet (112)
5. Remove valve plug (23)
6. Loosen and remove lower clamp (19)
7. Remove O-ring (21), lip seal (25) and bushing (24)
8. Remove seat (63) and O-ring (21) from valve body (26)
110
23
21
25
24
63
26
21
115
114
19
111
19
2405-0018_1
20