Alfalaval Unique SSV Series User manual

TD 461-583 TD 461-791
ESE00523-EN7 2020-02
Original manual
Instruction Manual
Unique Single Seat Valve - Manually Operated
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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 ............................................................................................ 9
3.4. Recycling information ............................................................................. 9
4. Operation ............................................................................................... 10
4.1. Operation .......................................................................................... 10
4.2. Troubleshooting ................................................................................... 12
4.3. Recommended cleaning ......................................................................... 13
5. Maintenance ........................................................................................... 15
5.1. General maintenance ............................................................................. 15
5.2. Dismantling the valve ............................................................................. 17
5.3. Plug seal replacement ............................................................................ 17
5.4. Valve assembly .................................................................................... 18
6. Technical data ......................................................................................... 19
6.1. Technical data ..................................................................................... 19
7. Parts list and service kits ............................................................................ 20
7.1. Drawing ............................................................................................ 20
7.2. Unique Single Seat Valve - Manual Operated Shut-off Valve ................................. 21
7.3. Unique Single Seat Valve - Manual Operated Change-over Valve ........................... 23
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1 EC Declaration of Conformity
Revision of Declaration of Conformity: 29/12-09
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Unique Single Seat Valve
Designation
Manually Operated
Type
is in conformity with the following directives:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A
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 2016-06-01
Place Date Signature
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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:
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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)
!
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 dismantle the valve when it is hot
Always read the technical data thoroughly (see chapter 6 Technical data)
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)
!
Never service the valve when it is hot
Never service the valve with valve and pipelines under pressure
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 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
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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 or change-over
valve.
2. Delivery note.
Step 2
2a
Shut-off valve:
1. Complete handle.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
TD 461-585
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).
TD 461-586_1
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.
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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 carefully.
See chapter 6 Technical data.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch moving parts during operation.
Moving parts!
TD 461-589
Step 3
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammering.
Avoid water
hammering!
Inlet
TD 461-590
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!
TD 461-591
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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.
Measurement A is depending on body combination and piping
solution.
It is recommended to fit sufficient clamps/unions to be able to
disassemble the valve for servicing
Please see actual PD-sheet for further information. TD 461-592_1
A
Step 2
Assemble the valve in accordance with the steps on page 18.
Pay special attention to the warnings!
TD 461-593
TD 461-614
Step 3
Pre-use check:
Open and close the valve several times to ensure that it operates
smoothly.
Pay special attention to the warnings!
TD 461-594
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 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
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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 carefully.
See chapter 6 Technical data.
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. Burn hazard!
TD 461-595
Step 3
Never touch moving parts during operation.
Moving parts!
TD 461-589
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 15).
Shut-off valve Change-over valve
TD 461-597
TD 461-615
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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 5
Lubrication of actuator
1. Ensure smooth movement of the crank mechanism (the cranck
is lubricated before delivery).
2. Lubricate all seals with Molykote Longterm 2 plus if necessary.
TD 461-598
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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 15!
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
- Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
- 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
Product pressure exceeds
actuator specification
Reduce product pressure
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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.
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!
TD 461-595
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
TD 461-599 Lift lower
valve plug
TD 461-600
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% by weight HNO3at 70oC
+=
Cleaning agent.
0.7 l
53% HNO3
100 l
water
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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.
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.
Always rinse!
Clean water Cleaning agents
Step 6
NOTE
The cleaning agents must be stored/disposed off in accordance
with current regulations/directives.
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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.
5.1 General maintenance
Step 1
Always read the technical data carefully.
See chapter 6 Technical data.
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 valve and pipelines under pressure.
Atmospheric
pressure
required!
Burn hazard!
TD 461-602
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.
Moving parts!
Cutting hazard!
TD 461-589
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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.
Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal
working conditionsinoneshift.
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
-Usethestat
istics for inspection planning
Replace after leakage
Lubrication
Before fitting
Klüber Paraliq GTE 703 or similar USDA H1
approved oil/grease
Pre-use check:
Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
TD 461-589
Recommended spare parts
Servicekits(seepage20)
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5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
5.2 Dismantling the valve
Step 1
1a
Shut-off valve:
1. Remove cap, loosen screw and remove the washer by
sliding it sideways.
2. Loosen and remove clamp.
3. Lift away the crank.
4. Remove valve plug.
5. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings! TD 461-959
Note! For plug seal replacement please see 17.
TD 461-601
1b
Change-over valve:
1. Loosen and remove lower clamp.
2. Lift away the crank and upper valve body.
3. Remove cap, loosen screw and remove the washer by
sliding it sideways.
4. Loosen and remove upper clamp.
5. Lift away the crank.
6. Remove valve body.
7. Remove seat and O-rings.
8. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
Note! Be careful not to damage the bushing.
Pay special attention to the warnings!
Note! For plug seal replacement please see 17.
TD 461-607_1
UP
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.
Note! For plug seal replacement please read instruction in service kit.
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5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
5.4 Valve assembly
Reverse order of 5.2 Dismantling the valve.
Lubricate O-ring (21) and lip seal (25) with Klüber Paraliq GTE 703.
Remember to tighten spindle and plug to a torque of 30Nm. (to use two 17mm spanners)
If there are vibrations in the pipeline Alfa Laval recommended using loctite no. 243.
The clamps thread must be lubricated before tightening - max. torque for the clamps is 10-12 Nm.
Note! Do not forget to screw in lower set screw (7) when assembling the valve.
It acts as a stroke stop. Without this screw the valve can be opened so far that the crank comes off.
Insomevalvesizestheflatsontheplugstemmayenter into the lip seal, which will then leak.
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6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform all personnel about the technical data.
6.1 Technical data
Data - valve
Max. product pressure 1000 kPa (10 bar).
Min. product pressure Full vacuum (depending on product specifications).
Temperature range -10oCto+140
oC(standardEPDMseal).
Materials - valve/crank mechanism
Product wetted steel parts 1.4404 (316L) (internal Ra < 0.8 µm).
Other steel parts 1.4301 (304).
Plug seal EPDM / PTFE (TR2).
Other product wetted seals EPDM (standard).
Optional product wetted seals HNBR and FPM.
Noise
One metre away from and 1.6 metres above the exhaust the noise level of a valve actuator will be approximately 77db (A)
without noise damper and approximately 72 db (A) with damper - measured at 7 bar air-pressure.
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7 Parts list and service kits
ThedrawingshowsUniqueSingleSeatValve-Manuallyoperated.
The items refer to the parts list in the following sections
7.1 Drawing
TD 461-666
TD 461-667
Shut-off Change-over
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