Alfalaval Unique SSV PN10 User manual

ESE00505-EN112022-11
Originalmanual
InstructionManual
UniqueSingleSeatValve-TwoStep

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................7
2.3.Safetprecautions................................................................................8
3.Installation....................................................................................11
3.1.Unpacking/deliver...............................................................................11
3.2.Generalinstallation................................................................................12
3.3.Welding............................................................................................14
3.4.Recclinginformation.............................................................................15
4.Operation.....................................................................................16
4.1.Descriptionafvalvefunction.....................................................................16
4.2.Operation..........................................................................................19
4.3.Troubleshooting...................................................................................21
4.4.Recommendedcleaning.........................................................................22
5.Maintenance..................................................................................24
5.1.Generalmaintenance.............................................................................24
5.2.Dismantlingthevalve.............................................................................26
5.3.Plugsealreplacement............................................................................27
5.4.Valveassembl....................................................................................30
5.5.Actuatortpes....................................................................................31
5.6.Actuatorbushingreplacement..................................................................32
5.7.Dismantlingof(NC)maintainableactuator.....................................................37
5.8.Dismantlingofchange-over(NO)maintainableactuator......................................39
5.9.Assemblofmaintainableactuator.............................................................40
5.10.Changingpneumaticmovementonfullmaintainableactuator(NC/NO)...................41
6.Technicaldata................................................................................43
6.1.Technicaldata.....................................................................................43
7.Partslistandservicekits...................................................................45
7.1.Drawing............................................................................................45
7.2.UniqueSingleSeatValve-TwoStep38-101.6mm-shut-offvalve.........................46
7.3.UniqueSingleSeatValve-TwoStep38-101,6mm-change-overvalve...................48
7.4.Mountingtool-UniqueSSV-TwoStepmaintainableactuator..............................50
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
UniqueSSVPN10
Tpe
Serialnumberfrom1000000to70000000000
isinconformitwiththefollowingdirectiveswithamendments:
-MachinerDirective2006/42/EC
-PressureEquipmentDirective2014/68/EUcategor1andsubjectedtoassessmentprocedureModuleA.Maonlbe
usedforfluidsinGroup2
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–11-18
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformitreplacesDeclarationofConformitdated2018-04-01
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
UniqueSSVPN10
Tpe
Serialnumberfrom1000000to70000000000
isinconformitwiththefollowingdirectiveswithamendments:
-TheSupplofMachiner(Safet)Regulations2008
-ThePressureEquipment(Safet)Regulations2016categor1andsubjectedtoassessmentprocedureModuleA.Ma
onlbeusedforfluidsinGroup2
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–11-18
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_112022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
2.1Importantinformation
Alwas Alwas
Alwasreadthemanualbeforeusingthevalve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjur.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimpliforclarifprocedures.
ThisInstructionmanualisdesignedtoprovidetheuserwiththeinformationtoperformtaskssafelforallphasesinthelifetimeof
theproductsupplied.
Theusershallalwasreadthesafetsectionfirst.Hereaftertheusercanskiptotherelevantsectionforthetasktobecarried
outorfortheinformationneeded.
Thisisthecompletemanualforthesuppliedproduct.
Operators Operators
Operators
Theoperatorsshallreadandunderstandtheinstructionmanualforthesuppliedproduct.
Maintenance Maintenance
Maintenancepersonnel personnel personnel
Themaintenancepersonnelshallreadandunderstandtheinstructionmanual.
Themaintenancepersonnelortechniciansshallbeskilledwithinthefieldrequiredtocarroutthemaintenanceworksafel.
T T
Trainees rainees rainees
Traineescanperformtasksunderthesupervisionofanexperiencedemploee.
People People
Peoplein in ingeneral general general
Thepublicshallnothaveaccesstothesuppliedproduct.
How How
Howto to tocontact contact contactAlfa Alfa AlfaLaval Laval Laval
Contactdetailsforallcountriesare
continuallupdatedonourwebsite.
Pleasevisitwww.alfalaval.comtoaccesstheinformationdirectl.
Dif Dif
Differ fer ferent ent entactuator actuator actuatortpes tpes tpesfor for forthe the theSSV SSV SSVvalve valve valve
InJune2016thebelowchangewasimplementedandthe“removableokewithbolts”versionistherebphasedoutand
replacedbthe“okewithoutbolts”version.
NOTE NOTE
NOTE
Itisimportanttocheckforwarningsmarkedontheactuatorwhenservicinganactuator-seebelowtable.
6

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
Full Full
Fullmaintainable maintainable maintainableactuator actuator actuator
Springcageandcanbeopened
Full Full
Fullmaintainable maintainable maintainableactuator actuator actuator
Springcageandcanbeopened
Actuator Actuator
Actuatortpe tpe tpe
“Removableokewithbolts”.
Iftheokewithboltsisdamagedithasto
bereplacedbthe“okewithoutbolts”
“Yokewithoutbolts”
Y Y
Yoke oke oketpe tpe tpe
YesYes
Service Service
Service
NoNo
Marked Marked
Markedwith with withwar war warnings nings nings
From2006toJune2016FromJune2016
Y Y
Year ear earof of ofpr pr production oduction oduction
2.2Warningsigns
Generalwarning
Causticagents
7

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontothisinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
2.3Safetyprecautions
Actuators Actuators
Actuators
Ifsupportairisutilised:
-ShockintheactuatormustNEVER NEVER
NEVERoccur
-SupportaironhighpressureactuatorversionsisNOT NOT
NOTallowed
Topreventshockintheactuatorandtopreventexceeding10bar/145PSIproductpressure,AlfaLavalrecommendsNOT NOT
NOTto
exceed3bar/43.5PSIsupportaironthespringsideinalltheUniqueSSVactuators.
Ifsupportairisconnectedalwasusethe3bar/43.5PSIairrelieffittings=9611995903.
Usingtheairrelieffittingalsoextendstheservicelifeoftheactuatorpistono-ring.
Pos. Pos.
Pos.no. no. no.5 5 5
Foractuators,manufacturedear2005-2018,withserialnumber
from1000000-5999999andfrom20000000000-59999999999
alwasusesteeladapter(pos5)=9614065301
Tightentorque=30Nm
Pos. Pos.
Pos.no. no. no.5 5 5
Foractuators,manufacturedear2019-->with
serialnumberfrom6000000to7000000andfrom
60000000000to70000000000alwasusesteel
adapter(pos5)=9615374701
Tightentorque=15Nm
Pos. Pos.
Pos.no. no. no.5 5 5
Foractuators,manufacturedear2005-2018,withserialnumberfrom1000000-5999999
andfrom20000000000-59999999999alwasusesteeladapter(pos5)=9614065301
Tightentorque=30Nm
Pos. Pos.
Pos.no. no. no.5 5 5
Foractuators,manufacturedear2019-->withserialnumberfrom6000000to7000000and
from60000000000to70000000000alwasusesteeladapter(pos5)=9615374701
Tightentorque=15Nm
8

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontothisinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
AlfaLavalrecommendsmax.3barsupportair
Alwasusethe“3barairrelieffittings”onsupportair.
AlfaLavalarticlenumber=9611995903
9

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontothisinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
Installation Installation
Installation
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Operation Operation
Operation
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Alwas Alwas
Alwasrinsewellwithcleanwateraftercleaning
Alwas Alwas
Alwashandleleandacidwithgreatcare
Maintenance Maintenance
Maintenance
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Neverservicethevalvewhenitishot
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure
Never Never
Neverstickourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Alwas Alwas
AlwasuseAlfaLavalgenuinespareparts
T T
Transportation ransportation ransportation
Alwas Alwas
Alwasensurethatcompressedairisreleased
Alwas Alwas
Alwasensurethatallconnectionsaredisconnectedbeforeattemptingtoremovethevalvefromthe
installation
Alwas Alwas
Alwasdrainliquidoutofvalvesbeforetransportation
Alwas Alwas
Alwasusepredesignedliftingpointsifdefined
Alwas Alwas
Alwasensuresufficientfixingofthevalveduringtransportation-ifspecialldesignedpackagingmaterial
isavailable,itmustbeused
STORAGE STORAGE
STORAGE
Ideall,asaguideAlfaLavalrecommend:
-Storesuppliedproductassuppliedinoriginalpackaging
-Portopeningshouldbeprotectedagainstaningress
-Baresteel(notstainless)shouldbelightloiled/greased
-Storeinaclean,drplacewithoutdirectsunlightorUVlight
-Temperaturerange-5to40°C
-Relativehumiditlessthan60%
-Noexposuretocorrosivesubstances(alsoaircontained).
10

3Installation
Theinstructionmanualispartofthedelivery.Studytheinstructionscarefully.
Theitemsrefertopartslistandservicekitssection.
Thevalveissuppliedasseparatepartsasstandardforwelding).
Thevalveisassembledbeforedelivery,ifitissuppliedwithfittings.
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
Alfa Alfa
AlfaLaval Laval Lavalcannot cannot cannotbe be beheld held heldr r responsible esponsible esponsiblefor for forincorr incorr incorrect ect ectunpacking. unpacking. unpacking.
Check Check
Checkthe the thedeliver deliver deliverfor: for: for:
1.Completevalve,shut-offvalveorchange-over
valve.
2.Delivernote.
Step Step
Step2 2 2
2a 2a
2a
Shut Shut
Shut- - -of of off f fvalve: valve: valve:
1.Completeactuator.
2.Bonnet(20).
3.Clamp(19).
4.Valveplug(23).
5.Valvebod(22).
2b 2b
2b
Change Change
Change- - -over over overvalve: valve: valve:
1.Completeactuator.
2.Bonnet(20).
3.2xclamps(19).
4.Valveplug(27).
5.Lowervalvebod(22).
6.Valveseat(28).
7.Uppervalvebod(26).
Step Step
Step3 3 3
Removepossiblepackingmaterialsfromthevalve/valveparts.
Inspectthevalve/valvepartsforvisibletransportdamage.
Avoiddamagingthevalve/valveparts.
11

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
3.2Generalinstallation
Step Step
Step1 1 1
-CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
-Alwas Alwas
Alwasreleasecompressedairafteruse.
-Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Seesection6Technicaldata.
Step Step
Step2 2 2
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwith
compressedair.
Moving Moving
Movingparts! parts! parts!Air
Air
Step Step
Step3 3 3
Toavoidwaterhammering,itisrecommendedtoinstallthevalve
sothattheflowisagainstthespringclosingdirection.
Shockintheactuatormustnever never
neveroccur.
A A
Avoid void voidwater water water
hammering! hammering!
hammering!
Air
Flow
Flow
Step Step
Step4 4 4
Avoidstressingthevalve.
Pa Pa
Paspecial special specialattention attention attentionto: to: to:
-Vibrations.
-Thermalexpansionofthepipelines.
-Excessivewelding.
-Overloadingofthepipelines.
Risk Risk
Riskof of ofdamage! damage! damage!
12

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
Step Step
Step5 5 5
Makesurethattheleakdetectionholeinthevalvebod:
1.isvisible,whenmountingthevalveverticall
2.alwasisdownwardsduetoself-draining,whenthevalveismountedhorizontall.
*=Leakagedetectionhole
13

3Installation
Studytheinstructionscarefully.
Thevalveissuppliedasseparatepartstofacilitatethewelding.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
3.3Welding
Step Step
Step1 1 1
Alwas Alwas
Alwasinstallvalveswithmorethanonevalvebodsothatthe
sealsbetweenthevalvebodiescanbereplaced.Donotweld
morethanonevalvebodintothesstem.Itisrecommendedto
fitsufficientclamps/unionstobeabletodisassemblethevalve
forservicing.
ValvesizeA(mm)B(mm)
DN40/38mm*740
DN50/51mm*770
DN65/63.5mm*780
DN80/76mm*830
DN100/101.6mm*880
*Dependingonbodcombinationandpipingsolution.
B(incl.topunit)
A*
Step Step
Step2 2 2
Assemblethevalveinaccordancewiththestepsonpage30.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Step Step
Step3 3 3
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.Supplcompressedairtotheactuator.
2.Openandclosethevalveseveraltimestoensurethatitoperatessmoothl.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
NCNOAir(TwoStepstroke)
Air(mainmovement)
Air(mainmovement)
Open/close!Air(TwoStepstroke)Open/close
14

3Installation
Studytheinstructionscarefully.
Thevalveissuppliedasseparatepartstofacilitatethewelding.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
3.4Recyclinginformation
Unpacking Unpacking
Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbereused,reccledorusedforenergrecover
-Plasticsshouldbereccledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialreccling
Maintenance Maintenance
Maintenance
-Duringmaintenance,oilandwearingpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialreccling
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialreccling
-Oilandallnon-metalwearingpartsmustbedisposedofinaccordancewithlocalregulations
Scrapping Scrapping
Scrapping
-Atendofuse,theequipmentmustbereccledinaccordancewiththerelevantlocalregulations.Besidestheequipment
itself,anhazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenin
doubt,orintheabsenceoflocalregulations,pleasecontactourlocalAlfaLavalsalescompan.Iftheactuatorismarked
withadangerwarning,donotattempttocuttheactuatoropen.
15

4Operation
Studytheinstructionscarefully.
Theitemrefertothepartsandservicekitssection.
NO=Normallyopenpneumaticmovementdownwards.
NC=Normallyclosedpneumaticmovementupwards.
4.1Descriptionafvalvefunction
TheSSVTwostepvalvehastwopistonsinsidetheactuator,whichmakesitpossibletohaveanintermediateplugposition
whereallbodendsareopen.
SSVTwostepvalvesaremadeinashut-offvalvetpeandachange-overvalvetpe.
Step Step
Step1a 1a 1a
T T
Tpe pe peshut shut shut- - -of of off f fvalve valve valve(onl (onl (onlNC) NC) NC)
Twostepvalvesasshut-off(onlasNC)canbeusedforreducingpressurehammersordosinge.g.inconnectionwithfillingof
avesselwhereanexactvolumeisrequired.
Thedegreeofopeningfortheintermediatepositioncanbeadjustedbremovingspacerringsinsidetheactuator(see
5.7Dismantlingof(NC)maintainableactuator).
Throttledpositioncanbe
adjustedbremovingspacers.
Plugopeningwillincreaseif
spacersareremoved
ClosedThrottledopening
Twostepstrokeactivated
Fullopen
Theplugopeningfordifferentshut-offvalvesandactuatorsizeisshownbelow.
Standar Standar
Standard d dactuator actuator actuatorchoice choice choice(NC) (NC) (NC)High High
Highpr pr pressur essur essure e eactuator actuator actuator
(NC) (NC)
(NC)
(Dimensions=mm)Inch Inch
Inchtube tube tubeDIN DIN DINtube tube tubeInch Inch Inchtube tube tubeDIN DIN DINtube tube tube
385163.576.1101.6405065801005163.55065
F F
Fmin. min. min.Twostepstroke(with
spacersinsideactuator)3332.52.53332.52.56666
F F
Fmax. max. max.Twostepstroke(spacers
removedinsideactuator)6111114146111114149999
S S
S=fullstrokeopening2025253030202525303025252525
16

4Operation
Studytheinstructionscarefully.
Theitemrefertothepartsandservicekitssection.
NO=Normallyopenpneumaticmovementdownwards.
NC=Normallyclosedpneumaticmovementupwards.
Step Step
Step1b 1b 1b
T T
Tpe pe pechange change change- - -over over overvalve valve valve(NC (NC (NCand and andNO) NO) NO)
Twostepvalvesaschange-over(NCandNO)canbeusedfordrainageoftwopipessimultaneouslorsplitofflowinthreelines.
Thevalvehasafixedintermediatepositionandspringreturntotheendpositions.
Spring Spring
Springr r retur etur eturn n nto to tolower lower lowerposition position position= = =NC NC NC
ClosedIntermediateposition
Twostepstrokeactivated
Open
Theplugopeningfordifferentchange-overvalvesandactuatorsizeisshownbelow.
Standar Standar
Standard d dactuator actuator actuatorchoice choice choice(NC) (NC) (NC)High High
Highpr pr pressur essur essure e eactuator actuator actuator(NC) (NC) (NC)
(Dimensions=mm)Inch Inch
Inchtube tube tubeDIN DIN DINtube tube tubeInch Inch Inchtube tube tubeDIN DIN DINtube tube tube
385163.576.1101.6405065801005163.55065
F F
F=fixedintermeidateposition6.5111114146.5111114149999
S S
S=fullstrokeopening1722222727172222272722222222
17

4Operation
Studytheinstructionscarefully.
Theitemrefertothepartsandservicekitssection.
NO=Normallyopenpneumaticmovementdownwards.
NC=Normallyclosedpneumaticmovementupwards.
Spring Spring
Springr r retur etur eturn n nto to toupper upper upperposition position position= = =NO NO NO
ClosedIntermediateposition
Twostepstrokeactivated
Open
Theplugopeningfordifferentchange-overvalvesandactuatorsizeisshownbelow.
Standar Standar
Standard d dactuator actuator actuatorchoice choice choice(NC) (NC) (NC)High High
Highpr pr pressur essur essure e eactuator actuator actuator
(NC) (NC)
(NC)
Dimensions=mmInch Inch
Inchtube tube tubeDIN DIN DINtube tube tubeInch Inch Inchtube tube tubeDIN DIN DINtube tube tube
385163.576.1101.6405065801005163.55065
F F
F=Fixedintermeidate
position1111111111111111111111111111
S S
S=fullstrokeopening1722222727172222272722222222
18

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Ensurethatthevalveoperatessmoothly.
Theitemsrefertothepartslistandservicekitssection.
4.2Operation
Step Step
Step1 1 1
-CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
-Alwas Alwas
Alwasreleasecompressedairafteruse.
-Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Seesection6Technicaldata.
-Alwas Alwas
AlwasuseAlfaLavalgenuinespareparts.
ThewarrantofAlfaLavalproductsisdependentonuseof
AlfaLavalgenuinespareparts.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghot
liquidsorwhensterilising.
Bur Bur
Burn n nhazar hazar hazard!! d!! d!!
Step Step
Step3 3 3
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwith
compressedair.
Moving Moving
Movingparts! parts! parts!Air
Air
19

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Ensurethatthevalveoperatessmoothly.
Theitemsrefertothepartslistandservicekitssection.
Step Step
Step4 4 4
Lubrication Lubrication
Lubricationof of ofvalves: valves: valves:
1.Ensuresmoothmovementbetweenlipseal(A)and
plugstem(B).
2.LubricatethelipsealwithAlfaLavalLubricantifnecessar
(seepage24).
Shut-offvalveChange-overvalve
Step Step
Step5 5 5
Lubrication Lubrication
Lubricationof of ofactuator actuator actuator
1.Ensuresmoothmovementoftheactuator(theactuatoris
lubricatedbeforedeliver).
2.LubricateallsealswithMolkoteLongterm2plusifnecessar.
Lubricate
20