Alfalaval Unique Valve User manual

2603-0000
ESE01525-EN2 2020-09
Original manual
Instruction Manual
Unique Vacuum Breaker 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/delivery ............................................................................... 7
3.2. General installation ................................................................................ 8
3.3. Important Installation Information ............................................................... 10
4. Operation ............................................................................................... 11
4.1. Operation .......................................................................................... 11
4.2. Troubleshooting ................................................................................... 13
4.3. Recommended cleaning ......................................................................... 14
5. Maintenance ........................................................................................... 16
5.1. General maintenance ............................................................................. 16
5.2. Dismantling of Unique Vacuum Breaker Valve ................................................. 17
5.3. Assembly of Unique Vacuum Breaker Valve ................................................... 18
5.4. Dismantling of actuator ........................................................................... 19
5.5. Assembly of actuator ............................................................................. 20
6. Technical data ......................................................................................... 21
6.1. Technical data ..................................................................................... 21
7. Parts list and service kits ............................................................................ 22
7.1. Unique Vacuum Breaker Valve .................................................................. 22
3

1 EC Declaration of Conformity
The designating company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Unique Valve Vacuum Breaker
Denomination Type Year
Was manufactured in conformity with the provisions in the COUNCIL DIRECTIVE on mutual approximation of the laws of the
Member States on the safety of machines (98/37/EC) with special reference to Annex 1 of the directive on essential safety and
health requirements in relation to the construction and manufacture of machines.
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment
Lars Kruse Andersen
Title Name
Alfa Laval Kolding
Company Signature
Designation
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
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:
5

2Safety
All warnings in the manual are summarized on this page.
Pay special attention to the 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 carefully.
Always release compressed air after use.
Never touch the 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 dismantle the valve when it is hot.
Operation
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always read the technical data carefully.
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilising.
Never touch the moving parts if the actuator is supplied with compressed air.
Always handle lye and acid with great care.
Maintenance
Always read the technical data carefully.
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 the moving parts if the actuator is supplied with compressed air.
6

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.
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.
2. Delivery note.
Step 2
Stop valve:
1. Complete actuator.
2. Ball (20).
3. 2 x clamp (21).
4. Stem (15).
5. Valve body (18).
6. O-ring (16).
7. Base (17).
8. Studt (22).
9. O-ring (23).
TD 474-002
21
22
15
16
18
21
20
23
17
Step 3
Inspect the valve/valve parts for visible transport damages.
Avoid damaging the valve/valve parts.
TD 474-003
Inspection!
7

3 Installation
Study the instructions carefully and pay special attention to the warnings!
3.2 General installation
Step 1
Always read the technical data carefully.
See chapter 6 Technical data
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Never touch the moving parts if the actuator is supplied with
compressed air.
Air
Moving parts!
2603-0001
Step 3
It is necessary to install the valve in the vertical position with the
actuator on top.
Fittings:
Ensure that connections are tight.
Remember seal rings
Inlet
2603-0002
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!
2603-0003
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Step 5
Air connections at actuator 1/4" Poly-Flow tubing or equivalent.
Air used only to pulse
valve during CIP
TD 474-003_1
9

3 Installation
Read the instructions carefully and pay special attention to the warnings.
The installation variation below is ONLY A SUGGESTION. It is important that you contact your local regulatory agency
for acceptance of your installation.
3.3 Important Installation Information
Step 1
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 (NO)
Open/close!
TD 474-003
Step 2
NOTE!
When installing C.I.P. drain pipe on the Vacuum Breaker discharge
port, ensure that an atmosphere break exists no lower than the
lowest point of the Vacuum Breaker. Ensure that the Vacuum
Breaker is situated 12" above the highest point of the raw product
pipeline on the pasteurized side.
C.I.P. Drain or atmospheric
port
TD 474-005
Pasteurized
Raw Product
12”minimum
HTST pasteurization system
Step 3
During product process, port acts as an atmospheric break in
case of power loss/failure. During C.I.P, the port acts as a C.I.P.
drain port.
Suggested installation
only
TD 474-006
Atmospheric break
10

4Operation
Study the instructions carefully and pay special attention to the warnings!
The vacuum breaker is automatically operated by means of an actuator.
4.1 Operation
Step 1
Always read the technical data carefully.
See chapter 6 Technical data
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Step 2
Never touch the vacuum breaker or the pipelines when processing
hot liquids or when sterilising.
Burning
danger!
2603-0004
Step 3
When pipelines are pressurized, the internal ball is forced upward,
closing the port.
2603-0001
Step 4
When internal pressure drops, the ball is drawn down, allowing air
to enter and relieve the vacuum.
2603-0005
11

4Operation
Study the instructions carefully and pay special attention to the warnings!
The vacuum breaker is automatically operated by means of an actuator.
Step 5
Operation by means of actuator: (C.I.P. only)
Automatic on/off operation by means of compressed air for pulsing
the actuator during C.I.P.
Air supply
TD 474-010_1
12

4Operation
Pay attention to possible faults. Study the instructions carefully.
4.2 Troubleshooting
Lubrication of actuator:
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate with grease if necessary.
2603-0006
3
9
11
3
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See page 16!
Problem Cause/result Repair
- External product leakage
- Internal leakage by closed valve
(normal wear)
- Worn seal ring/O-rings
-Wornball Replace the seal ring, O-rings and ball
- External leakage
- Internal leakage by closed valve
(too early)
- High pressure
-Hightemperature
- Aggressive liquids
- Many activations
- Replace by a seal ring of a
different rubber grade
- Change the operation conditions
Difficult to open/close - Worn O-rings
-Wornstem - Replace O-rings - Replace stem
Difficult to open/close The sealings seize Lubricate actuator parts:
-O-rings(3)
- O-rings (9) at inside of cylinder (1)
13

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
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.
NOTE
The cleaning agents must be stored/disposed off in accordance
with current regulations/directives.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
Never touch the vacuum breaker or the pipelines when processing
hot liquids or when sterilising. Burning danger!
2603-0004
Step 3
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 158oF
1kgNaOH +100 l water =Cleaning agent.
+=
Cleaning agent.
2.2 l
33% NaOH
100 l
water
2. 0.5% by weight HNO3at 158oF
+=
Cleaning agent.
0.7 l
53% HNO3
100 l
water
Step 4
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 5
NOTE
The cleaning agents must be stored/disposed off in accordance
with current regulations/directives.
14

4Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3=Nitricacid.
Step 6
Operation by means of actuator: (C.I.P. only)
Automatic on/off operation by means of compressed air for pulsing
the actuator during C.I.P.
Air supply
TD 474-010_1
15

5 Maintenance
Maintain the valve regularly.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals in stock.
Check the valve for smooth operation after service.
5.1 General maintenance
Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal
working conditions in one shift.
Valve rubber seals Actuator rubber seals
Preventive
maintenance
Replace after
12 months
Replace after
5 years
Maintenance after
leakage (leakage
normally starts slowly)
Replace at the
end of the day
Replace when
possible
Planned
maintenance
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the valve
- Use the statistics for
planning of inspections
Replace after leakage
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
planning of inspections
Replace after leakage
Lubrication Before fitting
USDA grade lubricant
Before fitting
Oil or grease
(USDA H1
approved oil/grease)
Pre-use check:
Air
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!
2603-0008
Recommended spare parts
Servicekits(seepage22)
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
5.2 Dismantling of Unique Vacuum Breaker Valve
Step 1
Always read the technical data carefully.
Always release compressed air before dismantling.
Step 2
The vacuum breaker must never be serviced while hot.
The vacuum breaker and the pipelines must never be serviced
while pressurized.
Step 3
1. Remove clamp from actuator/body.
2. Remove stem from actuator.
TD 474-011
Step 4
Remove O-ring.
TD 474-012
Step 5
1. Remove clamp from base/body.
2. Remove body, ball and gasket from the base.
TD 474-013
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
5.3 Assembly of Unique Vacuum Breaker Valve
Step 1
1. Assemble ball, gasket and body to the base.
2. Assemble the clamp and tighten.
TD 474-014
Step 2
1. Apply USDA grade lubricant to O-ring.
2. Assemble O-ring to stem.
3. Assemble stem to actuator.
TD 474-012
Step 3
Assemble actuator and stem to body.
TD 474-015
18

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section. Handle scrap correctly.
5.4 Dismantling of actuator
Step 1
1. Rotate cylinder (1).
2. Remove lock wire (12).
Rotate by hand or with
filter strap!
2603-0009
Step 2
1. Remove cylinder (1).
2. Remove O-rings (3, 11) from bonnet (13) and O-ring (3) from
cylinder (1).
2603-0010
Step 3
1. Remove piston/spring package.
2. Remove O-ring (9) from the piston (10).
2603-0011
Step 4
Replace the rubber seals.
2603-0012
19

5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
5.5 Assembly of actuator
Step 1
1. Fit O-ring (9) on piston (10).
2. Fit the piston/spring package.
2603-0011
Step 2
1. Fit O-rings (3, 11) in bonnet (13) and O-ring (3) on cylinder (1).
2. Fit the cylinder.
2603-0013
Step 3
1. Fit lock wire (12) through the slot in cylinder (1) into the hole
in bonnet (13).
2. Rotate the cylinder 360o(see step 4).
Rotate by hand or with
filter strap!
2603-0014
Step 4
NOTE!
It is recommended to rotate cylinder (1) further 180oin relation to
bonnet (13) so that the top and bottom air connections are fixed
on the same side.
2603-0015
20