Alfalaval Unique RV-ST User manual

2404-0022
ESE02127-EN3 2014-12
Original manual
Instruction Manual
Unique RV-ST 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. Installation .............................................................................................. 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 ............................................................................................ 9
3.4. Electrical connection ............................................................................. 10
3.5. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation .......................................................................................... 12
4.2. Troubleshooting ................................................................................... 14
4.3. Recommended cleaning ......................................................................... 15
5. Maintenance ........................................................................................... 17
5.1. General maintenance ............................................................................. 17
5.2. Dismantling of valve .............................................................................. 20
5.3. Plug seal replacement ............................................................................ 20
5.4. Assembly of valve ................................................................................. 21
5.5. Assembly instruction for positioner ............................................................. 21
5.6. Actuator bushing replacement .................................................................. 21
5.7. Dismantling of optional maintainable actuator ................................................. 22
5.8. Assembly of optional maintainable actuator ................................................... 22
5.9. Reversing optional maintainable actuator operation .......................................... 22
6. Technical data ......................................................................................... 23
6.1. Technical data positioner ......................................................................... 23
6.2. Technical data - valve/actuator .................................................................. 23
7. Parts list and service kits ............................................................................ 24
7.1. Unique RV-ST Regulating Valve - Shut-off valve ............................................... 24
7.2. Unique RV-ST Maintainable Actuator ........................................................... 26
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 SSV PN10
Type
From serial number 5099880 to 29999999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.
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 2012-04-01
Place Date Signature
4

2 Installation
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 severe 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 Installation
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 (see chapter 6 Technical data).
Always release compressed air after use.
Never touch the moving parts if compressed air is supplied to the actuator.
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 dismantlethevalvewhenitishot.
Operation
Always read the technical data thoroughly (see chapter 6 Technical data).
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never touch the moving parts if compressed air is supplied to the actuator.
Always rinse well with clean water after cleaning.
Always handle lye and acid with great care.
Maintenance
Always observe the technical data thoroughly (see chapter 6 Technical data).
Always release compressed air after use.
Never service the valve when it is hot.
The valve/actuator and the pipelines must never be pressurised when servicing the valve/actuator.
Never stick your fingers through the valve ports if the actuator is supplied with compressed air.
Never touch the moving parts if the actuator is supplied with compressed air.
Transportation
Always ensurethat compressed air are released.
Always ensurethat all connections are disconnected before attempting to remove the valve from the installation.
Always drain liquid out of valves before transportation.
Always use predesigned lifting points if defined.
Always encure adequate 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.
The items refer to the parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
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
1. Complete actuator
2. Bonnet (20)
3. Clamp (19)
4. Valve plug (23)
5. Valve body (22)
6. Positioner (77.1)
7. Adapter (82)
8. Spindle (79)
9. Special X-ring (80)
10. Allen screw (81)
11. Puck sensor pad (85)
12. O-ring (83)
13. Gasket for adapter (84)
79
80
77.1
82
81
84
83
85
20
23
19
22
2404-0008
Step 3
Remove possible packing materials from the valve/valve parts.
Inspect the valve/valve parts for visible transport damage.
Avoid damaging the valve/valve parts.
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.
3.2 General installation
Step 1
Always read the technical data thoroughly.
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch the moving parts if the actuator is supplied with
compressed air.
Moving parts!
2404-0007
Step 3
Avoid stressing the valve.
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes
- Excessive welding
- Overloading of the pipelines
2404-0009
Risk of damage!
8

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
Assemble the valve in accordance with the steps in chapter 5.4
Assembly of valve
Pay special attention to the warnings!
2404-0010
Step 2
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings! Air
Open/close
Air
2404-0011
9

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.4 Electrical connection
Electrical connection
Positioner 8694
Without display
Termi nal s tr i p
NC 1
NC 2
Not connected
NC 3
IN.0/4…20 mA + 4
PLC output signal IN.0/4…20 mA GND 5
Supply + 6
Power supply Supply GND 7
Positioner 8692
With display
Terminal strip
NC 1
NC 2
NC 3
Not connected
NC 4
5NC
6NC
7NC
8NC
9NC
Not connected
SET. 0/4…20 mA GND 10
PLC output signal SET. 0/4…20 mA + 11
Not connected NC 12
Supply GND 13
Power supply Supply + 14
10

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.5 Recycling information
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be reused, 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 wear 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 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
11

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.
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.
2404-0012
Danger of burns!
Step 3
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
2404-0013
Air
12

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 chapter 5.1 General maintenance).
Shut-off valve
2404-0014
25
23
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate O-ring(s) with Molykote Longterm 2 plus if necessary.
TD461-566_1
13

4Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits (chapter 7 Parts list and service kits).
4.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts. See chapter 5.1 General maintenance.
Problem Cause/result Repair
External product leakage Worn or product affected 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
- The product pressure on the plug is
too high
- Reduce product pressure
Water hammer The flow direction is the same as the
closing direction
- The flow direction should be against
the closing direction
The valve does not open/close - The pressure on the plug is too high - Reduce the product pressure
Deviation in the flow regulation - Mechanical parts have come loose
(vibrations)
- Tighten and adjust
Actuator does not regulate - No air Check air supply
- Actuator errors - Return the actuator to the supplier
-Positionererrors - Check positioner (see positioner
instruction)
14

4Operation
The valve is designed for cleaning in place (CIP).
NaOH = Caustic Soda.
HNO3 = Nitric acid.
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!
2404-0012
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily!
Shut-off valve
2404-0015
15

4Operation
The valve is designed for cleaning in place (CIP).
NaOH = Caustic Soda.
HNO3 = Nitric acid.
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC(158
oF) 2. 0.5% by weight HNO3at 70oC(158 oF)
1kg
(2.2 lbs)
NaOH
+
100 l
(26.4 gal)
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
+
100 l
(26.4 gal)
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.
Always rinse!
Clean water Cleaning agents
Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance with current rules/directives.
16

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.
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 rules/directives.
Step 2
Never service the valve when it is hot.
Never service the valve with the valve and pipelines under
pressure.
Atmospheric
pressure
required!
2404-0016
Danger of burns!
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air Danger of cutting!
2404-0013
Air
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.
Check the valve for smooth operation after service.
Step 4
Never touch the moving parts if compressed air is supplied to
the actuator.
Air
Moving
parts!
2404-0017
Air
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.
Check the valve for smooth operation after service.
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 Actuator bushings complete
Preventive maintenance Replace after 12 months depending on
working condition
Replace after 5 years depending on
working condition
Maintenance after leakage (leakage
normally starts slowly)
Replace at the end of the day Replace when possible
Planned maintenance - Regular inspection for leakage and
smooth operation
- Regular inspection for leakage and
smooth operation
- Keep a record of the valve - Keep a record of the actuator
- Use the statistics for inspection
planning
- Use the statistics for inspection
planning
Replace after leakage Replace after leakage
Lubrication Before fitting
Klüber Paraliq GTE 703 or similar USDA
H1 approved oil/grease
Before fitting
Molykote Longterm 2 plus
Air
Pre-use check:
1. Supply compressed air to the actuator
2. Open and close the valve several times to ensure that
it operates smoothly. Pay special attention to the
warnings!
Open/close
2404-0011
Air
Recommended spare parts
Service kits (see chapter 7 Parts list and service kits)
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 of valve
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Release compressed air (only NC)
4. Lift away the actuator.
5. Unscrew and remove valve plug.
6. Remove O-ring, lip seal and bushing in bonnet. (Use bushing
tool and rubber mallet).
Pay special attention to the warnings!
Note!
For plug seal replacement please see chapter 5.3 Plug seal
replacement
2404-0018
TD 461-837_1
5.3 Plug seal replacement
1. Remove old seal ring using a knife, screwdriver or similar.
Be careful not to damage metal parts.
2. Pre-mount plug seal without pressing it into the groove.
3. Squeeze plug seal into the groove using opposite pressure
points.
4. Release compressed air behind plug seal.
1
4
3
2
20