Alfalaval Unique TO User manual

TD 449-282_1
ESE00156-EN7 2017-03
Original manual
Instruction Manual
Unique-TO Mixproof Tank Outlet 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/intermediate storage ................................................................ 7
3.2. Recycling information ............................................................................. 9
3.3. General installation ................................................................................ 9
3.4. Welding ............................................................................................ 11
4. Operation ............................................................................................... 14
4.1. Operation .......................................................................................... 14
4.2. Fault finding and repair ........................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 19
5.1. General maintenance ............................................................................. 19
5.2. Dismantling of valve .............................................................................. 21
5.3. Tank plug, replacement of radial seal ........................................................... 24
5.4. Balanced plug, replacement of axial seal ....................................................... 25
5.5. Assembly of valve ................................................................................. 27
5.6. Dismantling of acutator ........................................................................... 30
5.7. Assembly of actuator ............................................................................. 32
6. Technical data ......................................................................................... 34
6.1. Technical data ..................................................................................... 34
7. Parts list and service kits ........................................................................... 36
7.1. Actuator ............................................................................................ 36
7.2. Plug setup 6 (tank flange) ........................................................................ 38
7.3. Plug setup 12 (tank flange) ...................................................................... 40
7.4. Plug setup 6 (stub flange) ........................................................................ 42
7.5. Plug setup 12 (stub flange) ...................................................................... 44
7.6. Valve bodies ....................................................................................... 46
7.7. Installation kit B ................................................................................... 48
7.8. Installation kit C ................................................................................... 50
7.9. Installation kit G ................................................................................... 52
7.10.Installation kit H and H2 .......................................................................... 54
7.11.Axial installation tool .............................................................................. 56
7.12.Radial installation tool ............................................................................ 58
7.13.Mounting tool for lip seal ......................................................................... 60
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique TO
Type
From serial number 1181354 - 9999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
- The valve is in compliance with the Pressure Equipment Directive 97/23/EC and was subjected to the following assessment
procedure Module A. Diameters ≥DN125 may not be used for fluids group 1.
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 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Important information
Alwaysreadthemanualbeforeusingthevalve!
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: Cutting danger:
5

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
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 clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Operation:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Never touch the clip assembly or the actuator piston rod when the actuator is supplied with compressed
air (see warning label)
Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing)
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never throttle the leakage outlet
Never throttle the CIP outlet, if supplied
Always handle lye and acid with great care
Maintenance:
Always read the technical data thoroughly (see chapter 6 Technical data) !
Always fit the seals correctly
Always release compressed air after use
Always remove the CIP connections, if supplied, before service
Never servicethevalvewhenitishot
Never pressurise the valve/actuator when the valve is serviced
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never service the valve with valve and pipelines under pressure
Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of
Alfa Laval genuine spare parts.
Transportation:
Always ensure that compressed air are released
Always ensure that all connections is 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
6

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is normally visible.
3.1 Unpacking/intermediate storage
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve
2. Delivery note
3. Warning label
Step 2
Remove upper support
TD 449-294_1
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
Step 4
Remove possible packing materials from the valve ports.
NOTE!
Remember to fit leakage
detection pipe
.
TD 449-235_1
7

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is normally visible.
Step 5
Inspect the valve for visible transport damages.
Inspection!
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections, if supplied.
Caution!
Step 7
Disassemble according to illustrations 1 to 5
(please also see 5.2 Dismantling of valve).
1. Supply compressed air.
2. Remove clamp
3. Release compressed air.
4. Lift out actuator with plugs.
5. Remove clamp.
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
Step 8
While valve body is welded, it is recommended to store the valve
safely in the box together with valve parts.
1. Place actuator and valve parts in the box.
2. Add supports.
3. Close, re-tape and store the box.
ADVISE!
Mark the valve body and box with the same number before
intermediate storage.
TD 449-300_1
3.2 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
3.3 General installation
Step 1
- Always read the technical data thoroughly (see 6 Technical data).
- Always release compressed air after use.
- Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see the warning label)
CAUTION!
- Fit the supplied warning label on the valve so that it is normally visible.
- Alfa Laval cannot be held responsible for incorrect installation
NOTE!
- The leakage outlet must be turned downwards!
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
Step 2
Avoid stressing the valve as this can result in deformation of
the sealing area and misfunction of the valve (leakage or faulty
indication).
Pay special attention to:
-Vibrations
-Thermal expansion of the tubes (especially at long tube
lengths)
-Excessive welding
-Overloading of the pipelines
NOTE!
Please follow Alfa Laval installation guidelines (literature code
ESE00040).
Risk of damage!
TD 449-241
Step 3
Fittings:
Ensure that the connections are tight.
Remember seal rings!
Step 4
Air connection: R 1/8” (BSP).
AC1: Cleaning of balanced plug.
AC2: Open valve.
AC3: Cleaning of tank plug.
Step 5
CIP connection (optional extra):
1. See description of cleaning - 4.3 Recommended cleaning.
2. Connect CIP correctly
NOTE!
*=Movingparts
Must be open for
inspection!
B=CIPout
C=CIPin TD 449-251_1
B
C
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 6
It is important to connect CIP inlet to the small inlet nozzle to avoid
built-up pressure in the cleaning chamber
CIP out CIP in
Align nozzle edges with recess in sealing element.
3.4 Welding
Step 1
Never stick your fingers in the operating parts of the valve if the
actuator is supplied with compressed air. Cutting danger!
Air
Step 2
Dismantle the valve in accordance with step 1, section 5.2 Dismantling of valve
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 3
Bottom of tank Bottom of tank
Tank flange (standard) Stub flange (option)
A1
TD 449-253_1
11
TD 449-252_1
1=Caution 1=Caution
Before welding the flange into the tank please note:
1. Maintain the minimum clearances "A" so that the actuator with
the internal valve parts can be removed - please see later this
section!
If there is a risk of foot damage, Alfa Laval recommends to leave
adistanceof120mm(4.7”)belowthevalve(lookatthespecific
built-in conditions).
Min. dimension Unique TO (all measures in mm) (1mm = 0.0394”)
Longstroke
DN/OD
DN/OD
2” 2½” 3” 4”
DN
2½” 3”
DN
Size
51 63.5 76.1 101.6 50 65 80 100 125 150 63.5 76.1 63 80
with tank flange (A1)579 646 659 753 577 652 667 755 805 890 700 713 706 721
with external cleaning and tank flange (A1)616 686 699 813 614 692 707 815 865 N/A 740 753 746 761
with stub flange (A) 588 655 668 762 586 661 676 764 814 899 709 722 715 730
with external cleaning and stub flange (A) 625 695 708 822 623 701 716 824 874 N/A 749 762 755 770
If ThinkTop is mounted, add 180 mm (7.1”) to dimension
N/A = Not available
2. Always use welding jig (can be ordered separately at Alfa
Laval) to ensure precision of flange after welding.
Only use pulsed arc welding and remember no gap
between flange and tank plate.
Tack weld always on the opposite side (8 segments with
filler metal).
Weld root if possible without filler metal. Welding of the
final run must be done in 8 segments to avoid crack.
Remember NOT to dismount welding jig before flange is
cold.
Welding jig
TD 449-244_1
4
8
51
26
7
3
Item no. Size Welding tool for tank flange
2”
9613-0999-01 51 mm DN50
2½”-3“
9613-0999-02 63.5 - 76.1 mm DN65-DN80
4”
9613-0999-036 101.6 mm DN100 - DN150
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 4
Warning!
Make sure to turn the valve body correctly - conical seat
downwards before welding.
NOTE!
Always weld the valve body into the pipeline, so that the seal ring
(76) can be replaced.
Step 5
Assemble the valve in accordance with 5.5 Assembly of valve after welding.
Pay special attention to the warnings and clamp torque (see 5.5 Assembly of valve).
Step 6
Pre-use check:
1. Supply compressed air to AC1, AC2 and AC3 one by one.
2. Operate the valve several times to ensure that it runs smoothly.
Pay special attention to the warnings!
Operate!
13

4Operation
The valve is tested before delivery.
Study the instructions carefully and pay special attention to the warnings!
Pay attention to possible faults.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
-Always read the technical data thoroughly (see 6 Technical data).
-Always release compressed air after use.
-Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air (see the warning label).
-Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing).
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 sterilizing. Burning danger!
14

4Operation
Study the maintenance instructions carefully before replacing worn parts. - See 5.1 General maintenance
4.2 Fault finding and repair
Problem Cause/result Repair
Leakage at the leakage detection
pipe (88)
- Particles between valve seats and
plug seals (56/74)
- Worn/product affected plug seal
rings (56/74)
- Plug not assembled correctly
- Remove the particles
- Check the plug seals
- Replace the plug seals
- Change rubber grade
- Assemble plug, see step 3,
section 5.5 Assembly of valve
Leakage at sealing element (48)/
upper plug (94)
Worn/product affected o-rings/lip
seal (38/39/46/49)
- Replace the o-rings/lip seal
- Change rubber grade
- Clean and if necessary replace guide
ring (45)
Leakage at clamp (64) and (65) - Too old/product affected o-rings
(76 and 47) valve body
- Loose clamp (64) or (65)
- Replace the o-rings
- Change rubber grade
- Tighten the clamp (max. 10 Nm)
CIP leakage
Leakage at spindle clamp (43)
Worn o-rings (40/67)
Damaged o-ring (39)
Worn/product affected lip seal (57)
Replace the o-rings
- Replace the o-ring
- Replace the plug seals
- Change rubber grade
Tank plug not returning to closed
position
- Wrong rubber grade
- Wrongly fitted gasket
- Mounted incorrectly (see 3.4 Welding)
- Change rubber grade
- Fit new gasket correctly
- Correct installation
Plug returns with uneven movements
(slip/stick effect)
- Wrong rubber grade
- Wrongly fitted gasket
- Mounted incorrectly (see 3.4 Welding)
- Change rubber grade
- Fit new gasket correctly
- Correct installation
15

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.
Internal leakage in the valve is externally visible by means of the leakage outlet.
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 sterilizing.
Burning danger!
Step 3
- Never throttle the leakage outlet
- Never throttle the CIP outlet, if supplied.
Risk of mixing due to overpressure).
A. = Leakage/CIP out
B. = CIP out
C. = CIP in
TD 449-247_1
A
TD 449-251_1
B
C
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 (158oF)
1kg(2.2lb)
NaOH +100 l (26.4 gal)
water =Cleaning agent. 0.7 l
53% HNO3
+100l(26.4gal)
water =Cleaning agent.
2.2 l (0.6 gal)
33% NaOH +100 l (26.4 gal)
water =Cleaning agent.
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= Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 5
1. Avoid excessive concentration of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the process
Milk sterilization/viscous liquids
⇒Increase the cleaning flow!
Step 6
Advisory seat lift cleaning periods
Cleaning periods of 1-2 seconds per CIP sequence.
Product Periods
Milk 1-2
Yoghurt 3-5
Beer 2-5
Cold wort 5-10
Step 7
Always rinse well with clean water after the cleaning.
NOTE!
The cleaning agents must be stored/disposed of in accordance
with current rules/directives.
Pay special attention to spillage of hot cleaning fluid/water.
Always rinse!
Clean water Cleaning agents
Step 8
1. Closed valve
A=Product
B= CIP
TD 449-293_1
A
B
Step 9
2. Seat lift cleaning with tank plug (optional)
(see step 6 page 19)
A=CIP
B=Product
C=CIPout
TD 449-291_1
A
B
C
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=Nitricacid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 10
3. Open valve
A=Product
B = Leakage detecting
TD 449-292_1
A
B
Step 11
4. Seat lift cleaning with balanced plug
(seeStep 6, )
A=Product
B=CIP
C=CIPout
A
B
C
TD 449-289_1
18

5 Maintenance
Maintain the valve/actuator regularly.
Study the instructions carefully and pay special attention to the warnings!
Always use genuine Alfa Laval spare parts, and keep spare rubber seals and guide rings in stock. Store seals in closed bag.
The items refer to the parts list and service kits section.
5.1 General maintenance
Step 1
-Always read the technical data thoroughly (see 6 Technical data).
-Always fit the seals correctly (risk of mixing).
-Always release the compressed air after use.
-Always remove the CIP connections, if supplied, before service.
NOTE!
All scrap must be stored/disposed of in accordance with current rules/directives.
Step 2
-Never service the valve when it is hot.
-Never service the valve with valve/actuator under pressure
-Never service the valve with fluid in the tank. Atmospheric pressure
required!
Burning danger!
Step 3
Never stick your fingers in operating parts of the valve if the
actuator is supplied with compressed air.
Cutting danger!
Air
TD 449-256_1
Step 4
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air (see the warning label).
Moving
parts!
Air
TD 449-257_1
19

5 Maintenance
Maintain the valve/actuator regularly.
Study the instructions carefully and pay special attention to the warnings!
Always use genuine Alfa Laval spare parts, and keep spare rubber seals and guide rings in stock. Store seals in closed bag.
The items refer to the parts list and service kits section.
Recommended spare parts: Service kits (see 6 Technical data)
Order service kits from the service kits section (see 6 Technical data)
Ordering spare parts: Contact the Sales Department.
The valve is designed so that internal leakages do not result in the products becoming mixed.
Internal leakage in the valve is externally visible. Study the instructions carefully.
Always keep spare rubber seals and guide rings in stock. Check the valve for smooth operation after service.
Valve rubber seals Valve plug seals Valve guide rings
Preventive maintenance Replace after 12 months(*) Replace after 12 months(*) Replace when required
Maintenance after leakage
(leakage normally starts slowly)
Replace after production
cycle
Replace after production
cycle
Planned maintenance - Regular inspection for
leakage and smooth
operation
- Keep a record of the valve
- Use the statistics for
planning of inspections
- Regular inspection for
leakage and smooth
operation
- Keep a record of the valve
- Use the statistics for
planning of inspections
Replace when required
Lubrication When assembling
Klüber Paraliq GTE 703 or similar
USDA H1 approved oil/grease (**)
(suitable for EPDM)
When assembling
Klüber Paraliq GTE 703 or similar
USDA H1 approved oil/grease (**)
(suitable for EPDM)
None
NOTE!
Lubricate thread in valve plug parts with Klüber Paste UH1 84-201 or similar.
(*) Depending on working conditions! Please contact Alfa Laval.
(**) All products wetted seals.
Repairing of actuator:
- The actuator is maintenance-free but repairable.
- If repair is required, replacing all actuator rubber seals is recommended.
- Lubricate seals with Molykote Longterm 2 (black).
- To avoid possible black remains on pos. 1 and 29, Alfa Laval recommends Klüber Paraliq GTE703 (white) for these two
positions.
Pre-use check
1. Supply compressed air to AC1, AC2 and AC3 one by one.
2. Operate the valve several times to ensure that it operates
smoothly.
Pay special attention to the warnings! Operate!
20