Alfalaval CPM-2 User manual

ESE01825-EN82022-10
Originalmanual
InstructionManual
CPM-2Constant-PressureModulatingValve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetprecautions................................................................................7
3.Installation....................................................................................8
3.1.Unpacking/deliver...............................................................................8
3.2.Generalinstallation................................................................................8
3.3.Welding............................................................................................10
3.4.Fittingofbooster(optionalextra)................................................................11
3.5.Recclinginformation.............................................................................13
4.Operation.....................................................................................15
4.1.Operation..........................................................................................15
4.2.Faultfinding.......................................................................................17
4.3.Recommendedcleaning.........................................................................18
5.Maintenance..................................................................................20
5.1.Generalmaintenance.............................................................................20
5.2.Dismantling........................................................................................21
5.3.Assembl..........................................................................................23
6.Technicaldata................................................................................26
6.1.Technicaldata.....................................................................................26
6.2.Selection/pressuredrop-capacitdiagram..................................................27
7.Partslistsandservicekit...................................................................29
7.1.CPM-2.............................................................................................29
7.2.Booster............................................................................................33
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
CPM-2
Tpe
isinconformitwiththefollowingdirectiveswithamendments:
-MachinerDirective2006/42/EC
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformitreplacesDeclarationofConformitdated2013-12-03
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
CPM-2
Tpe
isinconformitwiththefollowingdirectiveswithamendments:
-TheSupplofMachiner(Safet)Regulations2008
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
Allwarningsinthemanualaresummarizedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryordamagetothevalveareavoided.
2.1Importantinformation
Alwas Alwas
Alwasr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the thevalve! valve! valve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseverepersonalinjur.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimpliforclarifprocedures.
2.2Warningsigns
Generalwarning:
Causticagents:
6

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
Allwarningsinthemanualaresummarizedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryordamagetothevalveareavoided.
2.3Safetyprecautions
Installation Installation
Installation
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(Seechapter6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Nevertouchthevalvetopifcompressedairissuppliedtothevalve.
Thevalveandthepipelinesmust must
mustneverbepressurisedwhendismantlingthevalve.
Operation Operation
Operation
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(Seechapter6Technicaldata).
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilizing.
Never Never
Nevertouchthevalvetopifcompressedairissuppliedtothevalve.
Alwas Alwas
Alwashandleleandacidwithgreatcare.
Maintenance Maintenance
Maintenance
Alwas Alwas
Alwasobservethetechnicaldatathoroughl(Seechapter6Technicaldata).
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Neverservicethevalvewhenitishot.
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure.
T T
Transportation ransportation ransportation
Alwas Alwas
Alwassecurethatcompressedairisreleased.
Alwas Alwas
Alwassecurethatallconnectionsisdisconnectedbeforeattempttoremovethevalvefromtheinstallation.
Alwas Alwas
Alwasdrainliquidoutofvalvesbeforetransportation.
Alwas Alwas
Alwasusedpredesignedliftingpointsifdefined.
Alwas Alwas
Alwassecuresufficientfixingofthevalveduringtransportation-ifspecialdesignedpackagingmaterialisavailableit
mustbeused.
7

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
CPI-2:Constant-PressureodulatingInlet.
CPO-2:Constant-PressureodulatingOutlet.
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
Check Check
Checkthe the thedeliver: deliver: deliver:
1.Completevalve,CPMI-2orCPMO-2.
2.Delivernote.
3.Instructionmanual.
Step Step
Step2 2 2
Removepossiblepackingmaterialsfromthevalveports.
Avoiddamagingtheairconnectionandthevalveports.
Remove Remove
Removepacking packing packing
materials! materials!
materials!
Step Step
Step3 3 3
1.Inspectthevalveforvisibletransportdamage.
Inspection! Inspection!
Inspection!
3.2Generalinstallation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Nevertouchthevalvetopifcompressedairissuppliedtothe
valve.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
installation.
Step Step
Step2 2 2
Ensurethattheflowdirectioniscorrect.
CPMI CPMI
CPMI- - -2 2 2CPMO CPMO CPMO- - -2 2 2
InletCorr Corr
Correct ect ectOutlet
OutletInlet
8

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
CPI-2:Constant-PressureodulatingInlet.CPO-2:Constant-PressureodulatingOutlet.
Therequiredproductpressureispresetbymeansofanairpressureregulatingvalve(optionalextra).
Step Step
Step3 3 3
Avoidstressingthevalve.
Paspecialattentionto:
-Vibrations.
-Thermalexpansionofthetubes.
-Excessivewelding.
-Overloadingofthepipelines.
Risk Risk
Riskof of ofdamage! damage! damage!
Step Step
Step4 4 4
Fittings: Fittings:
Fittings:
Ensurethattheconnectionsaretight.
Remember Remember
Rememberseal seal sealrings! rings! rings!
Step Step
Step5 5 5
Air Air
Airconnection: connection: connection:R1/4"(BSP)
Air
Step Step
Step6 6 6
Air Air
Airpr pr pressur essur essure e er r regulating egulating egulatingvalve valve valve(optionalextra):
Anairpressureregulatingvalvemustbeusedandshouldbe
installedwithmin.clearancetotheBooster/CPM-2valve.
As As
Asclose close closeas as aspossible! possible! possible!
Pressureregulatingvalve
Air
9

3Installation
Studytheinstructionscarefully.
Thevalvehasweldingendsasstandard.Weldcarefully.
CPI-2:Constant-PressureodulatingInlet.
CPO-2:Constant-PressureodulatingOutlet.
3.3Welding
Step Step
Step1 1 1
DismantlethevalveinaccordancewithStep1-Step4inchapter
5.2Dismantling.
Paspecialattentiontothewarning!
Step Step
Step2 2 2
CPMI CPMI
CPMI- - -2: 2: 2:
1.Weldthevalvebodintothepipelines.
2.Maintaintheminimumclearancesothattheinternalvalveparts
canberemoved.
A=200mm(withoutbooster)/250mm(withbooster)
Step Step
Step3 3 3
CPMO CPMO
CPMO- - -2: 2: 2:
1.Weldthevalvebodintothepipelines(seealsoStep4).
2.Maintaintheminimumclearancesothatthevalveplugcan
beremoved.
A=150mm(withoutbooster)/200mm(withbooster)
B=250mm
Caution! Caution!
Caution!
Step Step
Step4 4 4
CPMO CPMO
CPMO- - -2: 2: 2:
Neverweldthebottomconnectionasthiswillmakeitimpossible
todismantlethevalve.Onlfittings!
Step Step
Step5 5 5
AssemblethevalveinaccordancewithStep6-Step10inchapter
5.3Assembl.
Tightenclamp10-15Nm(7.5-11lbf-ft)
10

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoallowforaproductpressurehigherthanavailableairpressure.
Step Step
Step6 6 6
Pr Pr
Pre e e- - -use use usecheck: check: check:
Liftandlowerthevalvetopseveraltimestoensurethatthevalve
operatessmoothl.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warning! ning! ning!
Liftandlowerbhand!
3.4Fittingofbooster(optionalextra)
Step Step
Step1 1 1
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquids
orwhensterilising.
Thevalveandthepipelinesmustnever never
neverbepressurisedwhen
dismantlingthevalve.
Atmospheric Atmospheric
Atmosphericpr pr pressur essur essure e er r requir equir equired! ed! ed!
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step2 2 2
1.RemovethevalvetopinaccordancewithStep3inchapter
5.2Dismantling
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
2.FitBoosterhousing(1)onthecover.
3.Fitandtightenlocknut(2).
11

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoallowforaproductpressurehigherthanavailableairpressure.
Step Step
Step3 3 3
1.Fitwasher(3).
2.Refitthewasherandthetopnutonthevalveplug.
Step Step
Step4 4 4
1.Turndiaphragm(7)insideout.
2.Placepiston(6)inthediaphragmsothattheholeisvisible.
Step Step
Step5 5 5
1.Rolldiaphragm(7)downhalfit’slenght.
2.Fitthediaphragmwithpiston(6)inBoosterhousing(1).
12

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoallowforaproductpressurehigherthanavailableairpressure.
Step Step
Step6 6 6
1.Fitcover(8)onBoosterhousing(1).
2.Fitandtightenclamp(9).
3.ThevalveandtheBoosterarenowreadforoperation.
Step Step
Step7 7 7
Compr Compr
Compressed essed essedair: air: air:
Anairpressurecompensatingregulatingvalvemustbeusedandshouldbeinstalledwithmin.clearancetotheBooster/
CPM-2valve.
Thepressureregulatingvalve(PR)andthepressuregauge(PG)areoptionalextras.
AlfaLavalrecommendsusingtheairpressureregulatingvalvefromAlfaLaval.
ø164
CPMI-2:232.4mm
CPMO-2:272.3mm
3.5Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbereused,reccledorusedforenergrecover
-Plasticsshouldbereccledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialreccling
• •
•Maintenance Maintenance Maintenance
-Duringmaintenanceoilandwearpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialreccling
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialreccling
13

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoallowforaproductpressurehigherthanavailableairpressure.
-Oilandallnonmetalwearpartsmustbetakencareofinagreementwithlocalregulations
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentshallbereccledaccordingtorelevant,localregulations.Besidetheequipmentitself,an
hazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactthelocalAlfaLavalsalescompan
14

4Operation
Thevalveislubricated,adjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
4.1Operation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Alwas Alwas
Alwasreleasecompressedairafteruse.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
operation.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquids
orwhensterilizing.
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step3 3 3
Never Never
Nevertouchthevalvetopifcompressedairissuppliedtothe
valve.
Cutting Cutting
Cuttingdanger! danger! danger!
Step Step
Step4 4 4
CAUTION! CAUTION!
CAUTION!
Theremustnotbevacuuminthevalveasaircanbedrawninto
theproductanddiaphragms(14)canthenbepulledoutfrom
supportsectors(12).
No No
Novacuum! vacuum! vacuum!
15

4Operation
Thevalveislubricated,adjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
Step Step
Step5 5 5
Lubrication: Lubrication:
Lubrication:
1.Ensuresmoothmovementbetweendiaphragms(10,14)
andsupportsectors(12).
2.Ensuresmoothmovementofguide(9).
Lubricateifnecessar!
(seechapter5.1Generalmaintenance)
16

4Operation
Payattentiontopossiblebreak-down.
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
4.2Faultnding
NOTE! NOTE!
NOTE!
Studthemaintenanceinstructionscarefullbeforereplacingwornparts-seechapter5Maintenance
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRepair Repair
Repair
Thevalvedoesnotmaintainthepreset
pressure
FaultdiaphragmReplacethediaphragm
Guide(9)seizesLubricatetheguide(seesection3.1)
IncorrectoperatingrangeCheckthepressuredropoverthevalve
andchecktheflowrate(seechapter
6.2Selection/pressuredrop-capacit
diagram)
Theavailableairpressureislowerthan
theproductpressure
Increasetheairpressureeg.busing
aBooster(seechapter3.4Fittingof
booster(optionalextra)).
TheairpressureisnotcorrectladjustedReadjusttheairpressure
Faultairpressureregulatingvalveor
incorrecttpe
Repairthevalveorcheckthatitis
pressurecompensating
ProductleakageWorndiaphragmReplacethediaphragm
Productaffecteddiaphragm
AirleakageWornO-ringReplacetheO-ring
Worndiaphragm(10)Replacethediaphragm
Wornandharddiaphragm(10)Replacebadiaphragmofadifferent
gradeforhighertemperature(seechapter
6.1Technicaldata)
Valveplugmovingtoofastupanddown
(unstable)
Pressurepulsationsbecauseoffast
changesinprocessconditions
Useanairthrottlingvalve(optionalextra
betweentheairpressureregulatingvalve
andtheCPM-2valve.
17

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.HNO3=Nitricacid.
4.3Recommendedcleaning
Step Step
Step1 1 1
Alwas Alwas
Alwashandleleandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Alwas Alwas
Alwasuse
rubbergloves!
Alwas Alwas
Alwasuse
protectivegoggles!
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhensterilizing.
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step3 3 3
CPMI CPMI
CPMI- - -2 2 2
EnsurethatthevalveisfullopentoallowformaximumCIPflow.
Full Full
Fullopen! open! open!
No No
Noair air air
pr pr
pressur essur essure! e! e!
CIPin
CIPout
Step Step
Step4 4 4
CPMO CPMO
CPMO- - -2 2 2Full Full
Fullopen! open! open!
Suf Suf
Sufficient ficient ficientair air air
pr pr
pressur essur essure! e! e!
CIPout
CIPin
18

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.HNO3=Nitricacid.
Step Step
Step5 5 5
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents: agents: agents:
Usecleanwater,freefromclorides.
1.1%bweightNaOHat70oC(158oF)2.0.5%bweightHNO3at70oC(158oF)
1kg(2.2lbs)
NaOH+100l
(26.4gal)water=Cleaningagent.0.7l(0.2gal)
53%HNO3+100l
(26.4gal)water=Cleaningagent.
2.2l(0.6gal)
33%NaOH+100l
(26.4gal)water=Cleaningagent.
Step Step
Step6 6 6
1.Avoidexcessiveconcentrationofthecleaningagent.
-Dose Dose
Dosegraduall graduall graduall.
2.Adjustthecleaningflowtotheprocess.
-Sterilization Sterilization
Sterilizationof of ofmilk/viscous milk/viscous milk/viscousliquids liquids liquids.
-Incr Incr
Increase ease easethe the thecleaning cleaning cleaningflow flow flow.
3.Alwas Alwas
Alwasrinsewellwithcleanwaterafterthecleaning.
NOTE NOTE
NOTE
Thecleaningagentsmustbestored/disposedofinaccordancewithcurrentrules/directives.
19

5Maintenance
aintainthevalvecarefully.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Alwayskeepsparediaphramsando-ringsinstock.
5.1Generalmaintenance
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
(Seechapter6.1Technicaldata)
Alwas Alwas
Alwasdisconnectthecompressedairbeforeservice.
NOTE NOTE
NOTE
Allscrapmustbestored/dischargedinaccordance
withcurrentrules/directives.
Step Step
Step2 2 2
Never Never
Neverservicethevalvewhenitishot.
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure.
Atmospheric Atmospheric
Atmosphericpr pr pressur essur essure e er r requir equir equired! ed! ed!
Bur Bur
Burning ning ningdanger! danger! danger!
Recommended Recommended
Recommendedspar spar spare e eparts: parts: parts:Service Service Servicekits kits kits(see (see (see7 7 7Parts Parts Partslists lists listsand and andservice service servicekit kit kit). ). ).
Orderservicekitsfromtheservicekitslist(see7Partslistsandservicekit)
Or Or
Ordering dering deringspar spar spare e eparts parts parts
ContacttheSalesDepartment.
Diaphragms Diaphragms
DiaphragmsO O
O- - -ring ring ring
Pr Pr
Preventive eventive eventivemaintenance maintenance maintenanceReplace Replace Replaceafter after after12 12 12months months monthsReplacewhenreplacingthediaphragms
Maintenance Maintenance
Maintenanceafter after afterleakage leakage leakage
(leakage (leakage
(leakagenormall normall normallstarts starts startsslowl) slowl) slowl)
Replace Replace
Replaceb b bthe the theend end endof of ofthe the theda da daReplacewhenreplacingthediaphragms
Planned Planned
Plannedmaintenance maintenance maintenance-Regularinspectionforleakageand
smoothoperation
-Keeparecordofthevalve
-Usethestatisticsforplanningof
inspections
Replacewhenreplacingdiaphragms
Replace Replace
Replaceafter after afterleakage leakage leakage
Lubrication Lubrication
Lubrication(befor (befor (before e eassembl) assembl) assembl)
Guide:Molcotelongtherm2Plus
Sectors:Molcote111.
Threads:MolcoteTP42.
20