Alfalaval Unique SSV PN10 User manual

2200-0073
ESE00674-EN10 2020-02
Original manual
Instruction Manual
Unique Single Seat Valve - ATEX Standard and Reverse Acting

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 .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 10
3.3. Welding ............................................................................................ 13
3.4. Recycling information ............................................................................. 14
4. Operation ............................................................................................... 15
4.1. Operation .......................................................................................... 15
4.2. Troubleshooting ................................................................................... 17
4.3. Recommended cleaning ......................................................................... 18
5. Maintenance ........................................................................................... 20
5.1. General maintenance ............................................................................. 20
5.2. Dismantling the valve ............................................................................. 22
5.3. Plug seal replacement ............................................................................ 24
5.4. Valve assembly .................................................................................... 27
5.5. Actuator bushing replacement (non-maintainable actuator) .................................. 28
6. Technical data ......................................................................................... 32
6.1. Technical data ..................................................................................... 32
7. Parts list and service kits ............................................................................ 34
7.1. Drawing - Unique Single Seat Valve - ATEX .................................................... 34
7.2. Unique Single Seat Valve - ATEX - shut-off .................................................... 35
7.3. Unique Single Seat Valve - ATEX - change-over ............................................... 37
7.4. Drawing Unique Single Seat Valve - ATEX - Reverse Acting ................................. 40
7.5. Unique Single Seat Valve - ATEX - Reverse Acting - shut-off ................................ 41
7.6. Unique Single Seat Valve - ATEX - Reverse Acting - change-over ........................... 43
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2018-04-01
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 1000000 to 70000000000
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A.
- Low Voltage Directive (LVD) 2014/35/EU
- EMC Directive 2014/30/EU
- DS/EN ISO 80079-36: Non-electrical equipment - Basic method and requirements
- DS/EN ISO 80079-37: Non-electrical equipment - Protection by constructional safety
- Technical file ref. 9612-9606. Baseefa (1180)
- The Notified Body NB.0044 will retain this Declaration of Conformity TÛV-Nord technical file no.: TÜV 08 ATEX 8000365231
If the valve is ATEX marked it is in conformity with:
- Equipment Explosive Atmospheres (ATEX) Directive 94/9/EC, valid until 2016-04-19
- Equipment Explosive Atmospheres (ATEX) Directive 2014/34/EU, valid from 2016-04-20
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 2018-04-01
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
Danger of injury: (an extra yellow label marked on the actuator from June 2016)
Do NOT attempt to cut the actuator open due to spring under load.
(The lock wire opening is locked). SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Danger of injury (lasermarked on the actuator)
Do NOT attempt to disassemble the actuator due to spring under load danger!
(The lock wire opening is locked) DO NOT DISASSEMBLE
kg
!
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
Actuators
If support air is utilised:
!
- Shock in the actuator must NEVER occur
- Support air on high pressure actuator versions is NOT allowed
To prevent shock in the actuator and to prevent exceeding 10 bar product pressure, Alfa Laval recommends NOT to exceed
3barsupporta
ir on the spring side in all the Unique SSV actuators.
If support air is connected always use the 3 bar air relief fittings = 9611995903.
Using the 3 bar air relief fitting also extends the service life of the actuator piston o-ring.
2200-0168_1
Ø26 (Ø1”)
Pos. no. 5
For actuators, manufactured year 2005-2018, with serial number from 1000000 - 5999999
and from 20000000000 - 59999999999 always use steel adapter (pos 5) = 9614065301
Tighten torque = 30 Nm
Ø19 (Ø3/4”)
2200-0169_1
Pos. no. 5
For actuators, manufactured year 2019 --> with serial number from 6000000 to 7000000 and
from 60000000000 to 70000000000 always use steel adapter (pos 5) = 9615374701
Tighten torque = 15 Nm
TD 461-990_2
5
Alfa Laval recommends max. 3 bar support air
Always use the “3 bar air relief fittings” on support air.
Alfa Laval article number = 9611995903
6

2 Safety
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.
INSTALLATION
Always read the technical data thoroughly (see section 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 dismantlethevalvewhenitishot
!
Never cut the actuator open, due to spring under load - if marked with this warning
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
DO NOT DISASSEMBLE
kg
!
OPERATION
Never dismantle the valve with valve and pipelines under pressure
Never dismantlethevalvewhenitishot
Always read the technical data thoroughly (see section 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 section 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
!
Never cut the actuator open, due to spring under load danger - if marked with this warning
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
DO NOT DISASSEMBLE
kg
!
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 out of 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
7

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to 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, shut-off valve (RA) or change-over
valve(RA)(seesteps2a,2b,2cand2d).
2. Delivery note.
Step 2
2a
Shut-off valve:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
6. Ground wire (64).
TD 461-943
64
2b
Change-over valve:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamps (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
8. Ground wire (64).
TD 461-944_1
64
UP
2c
Shut-off valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamps (19).
4. Valve plug (23).
5. 2 x upper valve bodies (26).
6. Valve seat (28).
7. Lower bonnet (33).
8. Ground wire (64).
TD 461-945_1
64
UP
8

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to 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.
2d
Change-over valve - Reverse Acting:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamps (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve bodies (26).
7. 2 x valve seats (28).
8. Lower bonnet (33).
9. Ground wire (64).
TD 461-946_1
64
UP
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.
9

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
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
-Always release compressed air after use.
-Always read the technical data thoroughly.
See section 6 Technical data.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to
spring under loaddanger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut
the actuator open, due to spring under load danger!
Step 2
!
Never touch moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
2200-0065
Step 3
To avoid water hammering, it is recommended to install the valve
so that the flow is against the spring closing direction.
Shock in the actuator must never occur.
Avoid water
hammering!
Air
Flow
Flow
2200-0155
10

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
Pay special attention to shock in the actuator due to support air.
Shock in the actuator must never occur.
*) Careful if using support air on spring side and a high product
pressure above the plug, as this can result in a high “hammer
effect” which can damage the actuator.
Use Alfa Laval part no. 9611995903, which ensures max. 3
bar support air pressure.
Alternatively remove the product pressure while activating the
plug.
Air
(Air)
Product pressure
2200-0121
*
Step 5
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines. Risk of damage!
2200-0067
11

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 6
Make sure that the leak detection hole in the valve body:
1. is visible, when mounting the valve vertically
2. always is downwards due to self-draining, when the valve is mounted horizontally.
2200-0172
***
*
* = Leakage detection hole
12

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the 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
Always install valves with more than one valve body so that the
seals between the valve bodies can be replaced. Do not weld
more than one valve body into the system. It is recommended to
fit sufficient clamps/unions to be able to disassemble the valve
for servicing.
Valve size A (mm) B (mm)
DN25/25 mm *630
DN40/38 mm *700
DN50/51 mm *750
DN65/63.5 mm *740
DN80/76 mm *800
DN100/101.6 mm *790
* Depending on body combination and piping solution.
B(incl.topunit)
A*
TD 461-015
Step 2
Assemble the valve in accordance with the steps on page 27.
Pay special attention to the warnings!
2200-0068
2200-0069
Step 3
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
Air
Open/close!
2200-0070
13

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
Step 4
Make sure the ground wire has electrical connection to plug and actuator.
!
All conducting parts or equipment must be arranged to avoid that a dangerous potential difference can exist between them.
If there is a possibility of isolated metal parts becoming charged and acting as an ignition source, then earthing terminals
must be provided.
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
-Duringmain
tenance, oil and wearing parts in the machine are replaced
-Allmetalpa
rts 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 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
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut the actuator open, due to spring under load danger!
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.
4.1 Operation
Step 1
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
-Always release compressed air after use.
-Always read the technical data thoroughly.
See section 6 Technical data.
-Always use Alfa Laval genuine spare parts.
The warranty of Alfa Laval products is dependent on use of
Alfa Laval genuine spare parts.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to
spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut
the actuator open, due to spring under load danger!
Step 2
!
Never touch the valve or the pipelines when processing hot
liquids or when sterilising.
Burn hazard!
2200-0071
Step 3
!
Never touch moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
Air
2200-0065
15

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, 27).
2. Lubricate the lip seal with Klüber Paraliq GTE 703 if necessary
(see page 20).
Shut-off valve Change-over valve
A
B
2200-0087
Step 5
Lubrication of actuator
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate all seals with Molykote Longterm 2 plus if necessary.
TD 461-1010
16

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 - see page 20.
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
- Product pressure exceeds
actuator specification - Replace with a high pressure actuator - Use auxiliary air on the spring side
(do not exceed 3 bar). Alfa Laval
article number = 9611995903.
See section 2.3 Safety precautions
and section 3.2 General installation
,Step4
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
- The flow direction should be
against the closing direction. See
section 3.2 General installation , Step
3
- Throttleairreleaseofsolenoidin
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Reduce product pressure
- Use auxiliary air on the spring side.
Always use the pressure relief fittings
(3 bar) on support side.
Alfa Laval article number =
9611995903
If marked with a danger warning, do NOT attempt to cut the actuator open, due to spring under load.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to cut the actuator open due to spring under load danger!
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= 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.
Burn hazard!
2200-0071
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and lower valve plug momentarily
Shut-off valve Change-over valve
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.
+=
Cleaning agent.
2.2 l
33% NaOH
100 l
water
2. 0.5%byweightHNO
3at 70oC
+=
Cleaning agent.
0.7 l
53% HNO3
100 l
water
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=Nitricacid.
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 the cleaning.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agents
Step 6
!
Dust cleaning!
To avoid damage, all seal openings must be held free for dust. All
surfaces must be cleaned for dust.
19

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
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
-Always release compressed air after use.
-Always read the technical data thoroughly.
See section 6 Technical data.
-Always use Alfa Laval genuine spare parts.
The warranty of Alfa Laval products is dependent on use of
Alfa Laval genuine spare parts.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to
spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut
the actuator open, due to spring under load danger!
Step 2
!
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.
Atmospheric
pressure
required!
Burn hazard!
2200-0072
Step 3
!
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.
Air
Moving parts!
Cutting hazard!
Air
2200-0065
20