Alfalaval Unique TO User manual

ESE00156-EN112022-10
Originalmanual
InstructionManual
Unique-TOMixproofTankOutletValve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetyprecautions................................................................................
3.Installation....................................................................................9
3.1.Unpacking/intermediatestorage................................................................9
3.2.Recyclinginformation.............................................................................11
3.3.Generalinstallation................................................................................11
3.4.Welding............................................................................................13
4.Operation.....................................................................................16
4.1.Operation..........................................................................................16
4.2.Faultfindingandrepair...........................................................................1
4.3.Recommendedcleaning.........................................................................18
5.Maintenance..................................................................................21
5.1.Generalmaintenance.............................................................................21
5.2.Dismantlingofvalve..............................................................................23
5.3.Tankplug,replacementofradialseal...........................................................26
5.4.Balancedplug,replacementofaxialseal.......................................................2
5.5.Assemblyofvalve.................................................................................29
5.6.Dismantlingofacutator...........................................................................33
5..Assemblyofactuator.............................................................................35
6.Technicaldata................................................................................37
6.1.Technicaldata.....................................................................................3
7.Partslistandservicekits..................................................................40
.1.Actuator............................................................................................40
.2.Plugsetup6(tankflange)........................................................................42
.3.Plugsetup12(tankflange)......................................................................44
.4.Plugsetup6(stubflange)........................................................................46
.5.Plugsetup12(stubflange)......................................................................48
.6.Valvebodies.......................................................................................50
..InstallationkitB...................................................................................52
.8.InstallationkitC...................................................................................54
.9.InstallationkitG...................................................................................56
.10.InstallationkitHandH2..........................................................................58
.11.Axialinstallationtool..............................................................................60
.12.Radialinstallationtool............................................................................62
.13.Mountingtoolforlipseal.........................................................................64
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Valve
Designation
UniqueTO
Type
Serialnumberfrom1181354to9999999
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-ThevalveisincompliancewiththePressureEquipmentDirective2014/68/ECandwassubjectedtothefollowing
assessmentprocedureModuleA.Diameters≥DN125maynotbeusedforfluidsgroup1.
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2013-12-03
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Valve
Designation
UniqueTO
Type
Serialnumberfrom1181354to9999999
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations2008
-ThePressureEquipment(Safety)Regulations2016category1andsubjectedtoassessmentprocedureModuleA.
Diameters≥DN125maynotbeusedforfluidsgroup1
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
2.1Importantinformation
Important Important
Importantinformation information information
Always Always
Alwaysr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the thevalve! valve! valve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmust must
mustbefollowedtoavoidseriouspersonalinjury.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmust must
mustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures.
ThisInstructionmanualisdesignedtoprovidetheuserwiththeinformationtoperformtaskssafelyforallphasesinthelifetimeof
theproductsupplied.
Theusershallalwaysreadthesafetysectionfirst.Hereaftertheusercanskiptotherelevantsectionforthetasktobecarried
outorfortheinformationneeded.
Thisisthecompletemanualforthesuppliedproduct.
Operators Operators
Operators
Theoperatorsshallreadandunderstandtheinstructionmanualforthesuppliedproduct.
Maintenance Maintenance
Maintenancepersonnel personnel personnel
Themaintenancepersonnelshallreadandunderstandtheinstructionmanual.
Themaintenancepersonnelortechniciansshallbeskilledwithinthefieldrequiredtocarryoutthemaintenanceworksafely.
T T
Trainees rainees rainees
Traineescanperformtasksunderthesupervisionofanexperiencedemployee.
People People
Peoplein in ingeneral general general
Thepublicshallnothaveaccesstothesuppliedproduct.
How How
Howto to tocontact contact contactAlfa Alfa AlfaLaval Laval Laval
Contactdetailsforallcountriesare
continuallyupdatedonourwebsite.
Pleasevisitwww.alfalaval.comtoaccesstheinformationdirectly.
2.2Warningsigns
Generalwarning:Causticagents:Cuttingdanger:
6

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
2.3Safetyprecautions
Installation: Installation:
Installation:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Always Always
Alwaysreleasecompressedairafteruse
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair
(seewarninglabel)
Never Never
Neverstickyourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Operation: Operation:
Operation:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodwhentheactuatorissuppliedwithcompressed
air(seewarninglabel)
Never Never
Neverpressuriseairconnections(AC1,AC3)simultaneouslyasbothvalveplugscanbelifted(cancausemixing)
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilizing.
Never Never
Neverthrottletheleakageoutlet
Never Never
NeverthrottletheCIPoutlet,ifsupplied
Always Always
Alwayshandlelyeandacidwithgreatcare
Maintenance: Maintenance:
Maintenance:
Always Always
Alwaysreadthetechnicaldatathoroughly(seechapter6Technicaldata)
Always Always
Alwaysfitthesealscorrectly
Always Always
Alwaysreleasecompressedairafteruse
Always Always
AlwaysremovetheCIPconnections,ifsupplied,beforeservice
Never Never
Neverservicethevalvewhenitishot
Never Never
Neverpressurisethevalve/actuatorwhenthevalveisserviced
Never Never
Neverstickyourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair
(seewarninglabel)
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure
Always Always
AlwaysuseAlfaLavalgenuinespareparts.ThewarrantyofAlfaLavalproductsisdependentontheuseof
AlfaLavalgenuinespareparts.
T T
Transportation: ransportation: ransportation:
Always Always
Alwaysensurethatcompressedairarereleased
Always Always
Alwaysensurethatallconnectionsisdisconnectedbeforeattemptingtoremovethevalvefromtheinstallation
Always Always
Alwaysdrainliquidoutofvalvesbeforetransportation
Always Always
Alwaysusedpredesignedliftingpointsifdefined
Always Always
Alwaysensuresufficientfixingofthevalveduringtransportation-ifspeciallydesignedpackagingmaterialisavailable,it
mustbeused
7

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
STORAGE STORAGE
STORAGE
Ideally,asaguideAlfaLavalrecommend:
-Storesuppliedproductassuppliedinoriginalpackaging
-Portopeningshouldbeprotectedagainstanyingress
-Baresteel(notstainless)shouldbelightlyoiled/greased
-Storeinaclean,dryplacewithoutdirectsunlightorUVlight
-Temperaturerange-5to40°C
-Relativehumiditylessthan60%
-Noexposuretocorrosivesubstances(alsoaircontained).
8

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
Fitthewarninglabelsuppliedonthevalveafterinstallationsothatitisnormallyvisible.
3.1Unpacking/intermediatestorage
Step Step
Step1 1 1
CAUTION! CAUTION!
CAUTION!
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
Check Check
Checkthe the thedelivery delivery deliveryfor: for: for:
1.Completevalve
2.Deliverynote
3.Warninglabel
Step Step
Step2 2 2
Removeuppersupport
Step Step
Step3 3 3
Liftoutthevalve.
NOTE! NOTE!
NOTE!
Pleasenoteweightofvalveasprintedonbox.
Step Step
Step4 4 4
Removepossiblepackingmaterialsfromthevalveports.
NOTE! NOTE!
NOTE!
Remembertofitleakage
detectionpipe
.
9

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
Fitthewarninglabelsuppliedonthevalveafterinstallationsothatitisnormallyvisible.
Step Step
Step5 5 5
Inspectthevalveforvisibletransportdamages.
Inspection! Inspection!
Inspection!
Step Step
Step6 6 6
Avoiddamagingtheairconnections,theleakageoutlet,thevalve
portsandtheCIPconnections,ifsupplied.
Caution! Caution!
Caution!
Step Step
Step
Disassembleaccordingtoillustrations1to5
(pleasealsosee5.2Dismantlingofvalve).
1.Supplycompressedair.
2.Removeclamp
3.Releasecompressedair.
4.Liftoutactuatorwithplugs.
5.Removeclamp.
10

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasendsforweldingasstandardbutcanalsobesuppliedwithfittings.
Step Step
Step8 8 8
Whilevalvebodyiswelded,itisrecommendedtostorethevalve
safelyintheboxtogetherwithvalveparts.
1.Placeactuatorandvalvepartsinthebox.
2.Addsupports.
3.Close,re-tapeandstorethebox.
ADVISE! ADVISE!
ADVISE!
Markthevalvebodyandboxwiththesamenumberbefore
intermediatestorage.
3.2Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbere-used,recycledorusedforenergyrecovery
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialrecycling.
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearingpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialrecycling
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialrecycling
-Oilandallnon-metalwearpartsmustbedisposedoffinagreementwithlocalregulations
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentmustberecycledaccordingtotherelevant,localregulations.Besidestheequipmentitself,any
hazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactyourlocalAlfaLavalsalescompany
3.3Generalinstallation
Step Step
Step1 1 1
-Alwaysreadthetechnicaldatathoroughly(see6Technicaldata).
-Alwaysreleasecompressedairafteruse.
-Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair
(seethewarninglabel)
CAUTION! CAUTION!
CAUTION!
-Fitthesuppliedwarninglabelonthevalvesothatitisnormallyvisible.
-AlfaLavalcannotbeheldresponsibleforincorrectinstallation
NOTE! NOTE!
NOTE!
-Theleakageoutletmustbeturneddownwards!
11

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasendsforweldingasstandardbutcanalsobesuppliedwithfittings.
Step Step
Step2 2 2
Avoidstressingthevalveasthiscanresultindeformationof
thesealingareaandmisfunctionofthevalve(leakageorfaulty
indication).
Pay Pay
Payspecial special specialattention attention attentionto: to: to:
-V V
Vibrations ibrations ibrations
-Thermal Thermal
Thermalexpansion expansion expansionof of ofthe the thetubes tubes tubes(especially (especially (especiallyat at atlong long longtube tube tube
lengths) lengths)
lengths)
-Excessive Excessive
Excessivewelding welding welding
-Overloading Overloading
Overloadingof of ofthe the thepipelines pipelines pipelines
NOTE! NOTE!
NOTE!
Please Please
Pleasefollow follow followAlfa Alfa AlfaLaval Laval Lavalinstallation installation installationguidelines guidelines guidelines(literatur (literatur (literature e ecode code code
ESE00040). ESE00040).
ESE00040).
Risk Risk
Riskof of ofdamage! damage! damage!
Step Step
Step3 3 3
Fittings:
Ensurethattheconnectionsaretight.
Remember Remember
Rememberseal seal sealrings! rings! rings!
Step Step
Step4 4 4
Airconnection:R1/8”(BSP).
AC1:Cleaningofbalancedplug.
AC2:Openvalve.
AC3:Cleaningoftankplug.
Step Step
Step5 5 5
CIPconnection(optionalextra):
1.Seedescriptionofcleaning-4.3Recommendedcleaning.
2.ConnectCIPcorrectly
NOTE! NOTE!
NOTE!
*=Movingparts
ThesepartswillovertimeturncounterclockwiseuntiltheVentpipe
touchtheedgeoftheintermediatepiece
Mustbeopenfor
inspection!
B=CIPout
C=CIPin
12

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasendsforweldingasstandard.
W W
Weld eld eldcarefully/aim carefully/aim carefully/aimat at atstressless stressless stresslesswelding welding weldingto to toavoid avoid avoiddeformation deformation deformationon on onsealing sealing sealingareas. areas. areas.
heck heck
heckthe the thevalve valve valvefor for forsmooth smooth smoothoperation operation operationafter after afterwelding. welding. welding.
Step Step
Step6 6 6
ItisimportanttoconnectCIPinlettothesmallinletnozzletoavoid
built-uppressureinthecleaningchamber
CIPoutCIPin
Alignnozzleedgeswithrecessinsealingelement.
3.4Welding
Step Step
Step1 1 1
Never Never
Neverstickyourfingersintheoperatingpartsofthevalveifthe
actuatorissuppliedwithcompressedair.Cutting Cutting
Cuttingdanger! danger! danger!
Air
Step Step
Step2 2 2
Dismantlethevalveinaccordancewithstep1,section5.2Dismantlingofvalve
13

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasendsforweldingasstandard.
W W
Weld eld eldcarefully/aim carefully/aim carefully/aimat at atstressless stressless stresslesswelding welding weldingto to toavoid avoid avoiddeformation deformation deformationon on onsealing sealing sealingareas. areas. areas.
heck heck
heckthe the thevalve valve valvefor for forsmooth smooth smoothoperation operation operationafter after afterwelding. welding. welding.
Step Step
Step3 3 3
BottomoftankBottomoftank
Tankflange(standard)Stubflange(option)
1=Caution1=Caution
Befor Befor
Before e ewelding welding weldingthe the theflange flange flangeinto into intothe the thetank tank tankplease please pleasenote: note: note:
1.Maintaintheminimumclearances"A"sothattheactuatorwith
theinternalvalvepartscanberemoved-pleaseseelaterthis
section!
Ifthereisariskoffootdamage,AlfaLavalrecommendstoleave
adistanceof120mm(4.”)belowthevalve(lookatthespecific
built-inconditions).
Min. Min.
Min.dimension dimension dimensionUnique Unique UniqueTO TO TO(allmeasuresinmm)(1mm=0.0394”)
Longstr Longstr
Longstroke oke oke
DN/OD DN/OD
DN/ODDN/OD DN/OD
DN/OD
2” 2”
2”2½” 2½”
2½”3” 3”
3”4” 4” 4”
DN DN
DN
2½” 2½”
2½”3” 3”
3”DN DN
DN
Size Size
Size
51 51
5163.5 63.5 63.56.1 6.1 6.1101.6 101.6 101.650 50 5065 65 6580 80 80100 100 100125 125 125150 150 15063.5 63.5 63.56.1 6.1 6.163 63 6380 80 80
withtankflange(A1)59646659535652665580589000130621
withexternalcleaningandtankflange(A1)6166866998136146920815865N/A40534661
withstubflange(A)58865566862586661666481489909221530
withexternalcleaningandstubflange(A)62569508822623011682484N/A4962550
IfThinkTopismounted,add180mm(.1”)todimension
N/A=Notavailable
2.Always Always
Alwaysuseweldingjig(canbeorderedseparatelyatAlfa
Laval)toensureprecisionofflangeafterwelding.
Only Only
Onlyusepulsedarcweldingandremembernogap
betweenflangeandtankplate.
Tackweldalways always
alwaysontheoppositeside(8segmentswith
fillermetal).
Weldrootifpossiblewithoutfillermetal.Weldingofthe
finalrunmustbedonein8segmentstoavoidcrack.
RememberNOT NOT
NOTtodismountweldingjigbeforeflangeis
cold.
Weldingjig
Item Item
Itemno. no. no.Size Size
SizeW W
Welding elding eldingtool tool toolfor for fortank tank tankflange flange flange
2”
961309990151mmDN50
2½”-3“
961309990263.5-6.1mmDN65-DN80
4”
9613099903101.6mmDN100-DN150
14

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasendsforweldingasstandard.
W W
Weld eld eldcarefully/aim carefully/aim carefully/aimat at atstressless stressless stresslesswelding welding weldingto to toavoid avoid avoiddeformation deformation deformationon on onsealing sealing sealingareas. areas. areas.
heck heck
heckthe the thevalve valve valvefor for forsmooth smooth smoothoperation operation operationafter after afterwelding. welding. welding.
Step Step
Step4 4 4
W W
War ar arning! ning! ning!
Makesuretoturnthevalvebodycorrectly-conicalseat
downwardsbeforewelding.
NOTE! NOTE!
NOTE!
Alwaysweldthevalvebodyintothepipeline,sothatthesealring
(6)canbereplaced.
Step Step
Step5 5 5
Assemblethevalveinaccordancewith5.5Assemblyofvalveafterwelding.
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings nings ningsand and andclamp clamp clamptor tor torque que que(see (see (see5.5 5.5 5.5Assembly Assembly Assemblyof of ofvalve valve valve). ). ).
Step Step
Step6 6 6
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.SupplycompressedairtoAC1,AC2andAC3onebyone.
2.Operatethevalveseveraltimestoensurethatitrunssmoothly.
Pay Pay
Payspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Operate! Operate!
Operate!
15

4Operation
Thevalveistestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Payattentiontopossiblefaults.
Theitemsrefertothepartslistandservicekitssection.
4.1Operation
Step Step
Step1 1 1
-Always Always
Alwaysreadthetechnicaldatathoroughly(see6Technicaldata).
-Always Always
Alwaysreleasecompressedairafteruse.
-Never Never
Nevertouchtheclipassemblyortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair(seethewarninglabel).
-Never Never
Neverpressuriseairconnections(AC1,AC3)simultaneouslyasbothvalveplugscanbelifted(cancausemixing).
CAUTION! CAUTION!
CAUTION!
AlfaLavalcannotbeheldresponsibleforincorrectoperation.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquids
orwhensterilizing.Bur Bur
Burning ning ningdanger! danger! danger!
16

4Operation
Studythemaintenanceinstructionscarefullybeforereplacingwornparts.-See5.1Generalmaintenance
4.2Faultndingandrepair
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRepair Repair
Repair
Leakageattheleakagedetection
pipe(88)
-Particlesbetweenvalveseatsand
plugseals(56/4)
-Worn/productaffectedplugseal
rings(56/4)
-Plugnotassembledcorrectly
-Removetheparticles
-Checktheplugseals
-Replacetheplugseals
-Changerubbergrade
-Assembleplug,seestep3,
section5.5Assemblyofvalve
Leakageatsealingelement(48)/
upperplug(94)
Worn/productaffectedo-rings/lip
seal(38/39/46/49)
-Replacetheo-rings/lipseal
-Changerubbergrade
-Cleanandifnecessaryreplaceguide
ring(45)
Leakageatclamp(64)and(65)-Tooold/productaffectedo-rings
(6and4)valvebody
-Looseclamp(64)or(65)
-Replacetheo-rings
-Changerubbergrade
-Tightentheclamp(max.10Nm)
CIPleakage
Leakageatspindleclamp(43)
Worno-rings(40/6)
Damagedo-ring(39)
Worn/productaffectedlipseal(5)
Replacetheo-rings
-Replacetheo-ring
-Replacetheplugseals
-Changerubbergrade
Tankplugnotreturningtoclosed
position
-Wrongrubbergrade
-Wronglyfittedgasket
-Mountedincorrectly(see3.4Welding)
-Changerubbergrade
-Fitnewgasketcorrectly
-Correctinstallation
Plugreturnswithunevenmovements
(slip/stickeffect)
-Wrongrubbergrade
-Wronglyfittedgasket
-Mountedincorrectly(see3.4Welding)
-Changerubbergrade
-Fitnewgasketcorrectly
-Correctinstallation
17

4Operation
Thevalveisdesignedforcleaninginplace(=IP).
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=austicSoda.HNO3=Nitricacid.
Internalleakageinthevalveisexternallyvisiblebymeansoftheleakageoutlet.
4.3Recommendedcleaning
Step Step
Step1 1 1
Always Always
Alwayshandlelyeandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Always Always
Alwaysuse
rubbergloves!
Always Always
Alwaysuse
protectivegoggles!
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhensterilizing.
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step3 3 3
-Neverthrottletheleakageoutlet
-NeverthrottletheCIPoutlet,ifsupplied.
Riskofmixingduetooverpressure).
A.=Leakage/CIPout
B.=CIPout
C.=CIPin
Step Step
Step4 4 4
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents agents agents:
Usecleanwater,freefromchlorides.
1.1%byweightNaOHat0oC(158oF)2.0.5%byweightHNO3at0oC(158oF)
1kg(2.2lb)
NaOH+100l(26.4gal)
water=Cleaningagent.0.l
53%HNO3+100l(26.4gal)
water=Cleaningagent.
2.2l(0.6gal)
33%NaOH+100l(26.4gal)
water=Cleaningagent.
18

4Operation
Thevalveisdesignedforcleaninginplace(=IP).
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=austicSoda.HNO3=Nitricacid.
Internalleakageinthevalveisexternallyvisiblebymeansoftheleakageoutlet.
Step Step
Step5 5 5
1.Avoidexcessiveconcentrationofthecleaningagent
⇒Dose Dose
Dosegradually! gradually! gradually!
2.Adjustthecleaningflowtotheprocess
Milk Milk
Milksterilization/viscous sterilization/viscous sterilization/viscousliquids liquids liquids
⇒Incr Incr
Increase ease easethe the thecleaning cleaning cleaningflow! flow! flow!
Step Step
Step6 6 6
V V
Valve alve alvepneumatic pneumatic pneumaticoperation operation operationduring during duringin in in- - -place place placecleaning cleaning cleaning
Eachvalveseatshallbeliftedduringthelengthofthecleaningcycle.
Seatliftdurationsshallnotexceed10seconds.
Thesepneumaticfunctionsinclude:
1.Uppervalveseatlift(takesplaceduringcleaningofuppervalvebody)
2.Lowervalveseatpush(takesplaceduringcleaningoflowervalvebody)
Thefollowingchartpresentsanoverviewofthesefunctionstogetherwiththerecommendedtimedurationsat21psi(1.5bar)CIP
pressure.Itisrecommendedtodoseatlift/pushinthemiddleofeachstepintheCIPsequence.
CIP CIP
CIPevent event event@ @ @length length lengthV V
Valve alve alvefunction function functionV V
Valve alve alve
solenoid solenoid
solenoidno. no. no.
Solenoid Solenoid
Solenoid
mode mode
mode
Actual Actual
Actualopening opening opening
time time
time
Number Number
Numberof of oflifts/push lifts/push lifts/push
in in
ineach each eachCIP CIP CIPstep step step
Upperseatlift3Energized*0.5sec3
Lowerseatlift2Energized*0.5sec3
SpiralCleanvent--*0.5sec3
Warmpre-rinse@
3minutesODcleaning--*5sec2
Upperseatlift3Energized*0.5sec3
Lowerseatlift2Energized*0.5sec3
SpiralCleanvent--*0.5sec3
Hotalkalinewash
@10minutesODcleaning--*5sec2
Upperseatlift3Energized*0.5sec3
Lowerseatlift2Energized*0.5sec3
SpiralCleanvent--*0.5sec3
Coldpostwash@
3minutesODcleaning--*5sec2
Upperseatlift3Energized*0.5sec3
Lowerseatlift2Energized*0.5sec3
SpiralCleanvent--*0.5sec3
Coldacidifiedrinse
@3minutesODcleaning--*5sec2
*Timestatedistheactualopeningtimeforthevalve.Programmeddurationisdependedontheaccesstocompressedairandresponse
timefromPLC.
Variationscausedbycompressedairaretypically:
-Longcompressedairsupplyhoses.
-SmallIDonairsupplyhoses.
-Limitedavailabilityofcompressedair.
Step Step
Step
Always Always
Alwaysrinsewellwithcleanwaterafterthecleaning.
NOTE! NOTE!
NOTE!
Thecleaningagentsmustbestored/disposedofinaccordance
withcurrentrules/directives.
Pay Pay
Payspecial special specialattention attention attentionto to tospillage spillage spillageof of ofhot hot hotcleaning cleaning cleaningfluid/water fluid/water fluid/water. . .
Always Always
Alwaysrinse! rinse! rinse!
CleanwaterCleaningagents
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4Operation
Thevalveisdesignedforcleaninginplace(=IP).
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=austicSoda.HNO3=Nitricacid.
Internalleakageinthevalveisexternallyvisiblebymeansoftheleakageoutlet.
Step Step
Step8 8 8
1. 1.
1.Closed Closed Closedvalve valve valve
A=Product
B=CIP
Step Step
Step9 9 9
2. 2.
2.Seat Seat Seatlift lift liftcleaning cleaning cleaningwith with withtank tank tankplug plug plug(optional) (optional) (optional)
(seestep6page19)
A=CIP
B=Product
C=CIPout
Step Step
Step10 10 10
3. 3.
3.Open Open Openvalve valve valve
A=Product
B=Leakagedetecting
Step Step
Step11 11 11
4. 4.
4.Seat Seat Seatlift lift liftcleaning cleaning cleaningwith with withbalanced balanced balancedplug plug plug
(seeStep6,)
A=Product
B=CIP
C=CIPout
20