Alfalaval CPM-I-D60 User manual

ESE01834-EN52022-11
Originalmanual
InstructionManual
CPM-I-D60Constant-PressureModulatingInletValve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Saftyprcautions................................................................................7
3.Installation....................................................................................8
3.1.Unpacking/dlivry...............................................................................8
3.2.Gnralinstallation................................................................................9
3.3.Wlding............................................................................................11
3.4.FittingofBoostr(optionalxtra)................................................................13
3.5.Rcyclinginformation.............................................................................15
4.Operation.....................................................................................16
4.1.Opration..........................................................................................16
4.2.Faultfinding.......................................................................................18
4.3.Rcommnddclaning.........................................................................19
5.Maintenance..................................................................................21
5.1.Gnralmaintnanc.............................................................................21
5.2.Dismantling........................................................................................23
5.3.Assmbly..........................................................................................26
6.Technicaldata................................................................................30
6.1.Tchnicaldata.....................................................................................30
6.2.Slction/Prssurdrop-capacitydiagram.................................................31
7.Partslistsandservicekit...................................................................33
7.1.CPM-I-D60........................................................................................33
7.2.Boostr............................................................................................37
3

1DeclarationsofConformity
EU EU
EUDclaration Dclaration Dclarationof of ofConformity Conformity Conformity
ThDsignatdCompany
AlfaLavalKoldingA/S,Albun31,DK-6000Kolding,Dnmark,[phone]
Companynam,addrssandphonnumbr
Hrbydclarthat
Valv
Dsignation
CPM-I-D60
Typ
isinconformitywiththfollowingdirctivswithamndmnts:
-MachinryDirctiv2006/42/EC
Thprsonauthorisdtocompilthtchnicalfilisthsignrofthisdocumnt.
GlobalProductQualityManagrLarsKrusAndrsn
TitlNam
Kolding,Dnmark2022–11-18
PlacDat(YYYY-MM-DD)Signatur
ThisDclarationofConformityrplacsDclarationofConformitydatd2016-06-06
4

1DeclarationsofConformity
UK UK
UKDclaration Dclaration Dclarationof of ofConformity Conformity Conformity
ThDsignatdCompany
AlfaLavalKoldingA/S,Albun31,DK-6000Kolding,Dnmark,[phone]
Companynam,addrssandphonnumbr
Hrbydclarthat
Valv
Dsignation
CPM-I-D60
Typ
isinconformitywiththfollowingdirctivswithamndmnts:
-ThSupplyofMachinry(Safty)Rgulations2008
Signdonbhalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagrLarsKrusAndrsn
TitlNam
Kolding,Dnmark2022–11-18
PlacDat(YYYY-MM-DD)Signatur
DoCRvison_01_112022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
2.1Importantinformation
Always Always
Alwaysr r rad ad adth th thmanual manual manualbfor bfor bfor using using usingth th thvalv! valv! valv!
W W
WARNING ARNING ARNING
Indicatsthatspcialprocdursmustbfollowdtoavoidsvrprsonalinjury.
CAUTION CAUTION
CAUTION
Indicatsthatspcialprocdursmustbfollowdtoavoiddamagtothvalv.
NOTE NOTE
NOTE
Indicatsimportantinformationtosimplifyorclarifyprocdurs.
2.2Warningsigns
Gnralwarning:
Causticagnts:
6

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
2.3Safetyprecautions
Installation Installation
Installation
Always Always
Alwaysradthtchnicaldatathoroughly(Schaptr6Tchnicaldata)
Always Always
Alwaysrlascomprssdairaftrus.
Nvr Nvr
Nvrtouchthvalvtopifcomprssdairissupplidtothvalv.
Thvalvandthpiplinsmust must
mustnvrbprssurisdwhndismantlingthvalv.
Opration Opration
Opration
Always Always
Alwaysradthtchnicaldatathoroughly(Schaptr6Tchnicaldata).
Always Always
Alwaysrlascomprssdairaftrus.
Nvr Nvr
Nvrtouchthvalvorthpiplinswhnprocssinghotliquidsorwhnstrilizing.
Nvr Nvr
Nvrtouchthvalvtopifcomprssdairissupplidtothvalv.
Always Always
Alwayshandllyandacidwithgratcar.
Maintnanc Maintnanc
Maintnanc
Always Always
Alwaysobsrvthtchnicaldatathoroughly(Schaptr6Tchnicaldata).
Always Always
Alwaysrlascomprssdairaftrus.
Nvr Nvr
Nvrsrvicthvalvwhnitishot.
Nvr Nvr
Nvrsrvicthvalvwithvalvandpiplinsundrprssur.
T T
Transportation ransportation ransportation
Always Always
Alwaysscurthatcomprssdairisrlasd.
Always Always
Alwaysscurthatallconnctionsisdisconnctdbforattmpttormovthvalv
fromthinstallation.
Always Always
Alwaysdrainliquidoutofvalvsbfortransportation.
Always Always
Alwaysusdprdsigndliftingpointsifdfind.
Always Always
Alwaysscursufficintfixingofthvalvduringtransportation-ifspcialdsignd
packagingmatrialisavailablitmustbusd.
7

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
3.1Unpacking/delivery
Stp Stp
Stp1 1 1
CAUTION CAUTION
CAUTION
AlfaLavalcannotbhldrsponsiblforincorrctunpacking.
Chck Chck
Chckth th thdlivry: dlivry: dlivry:
1.Compltvalv.
2.Dlivrynot.
3.Instructionmanual.
Stp Stp
Stp2 2 2
Rmovpossiblpackingmatrialsfromthvalvports.* *
*= = =Rmov Rmov Rmovpacking packing packingmatrials! matrials! matrials!
Stp Stp
Stp3 3 3
1.Inspctthvalvforvisibltransportdamag.
Stp Stp
Stp4 4 4
Avoiddamagingthairconnctionandthvalvports.
8

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
Therequiredproductpressureispresetbymeansofanairpressureregulatingvalve(optionaletra).
3.2Generalinstallation
Stp Stp
Stp1 1 1
Always Always
Alwaysradthtchnicaldatathoroughly.
Always Always
Alwaysrlascomprssdairaftrus.Nvr Nvr Nvrtouchthvalvtopifcomprssdairissupplidtothvalv.
Nvr Nvr
Nvrtouchthvalvtopifcomprssdairissupplidtothvalv.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbhldrsponsiblforincorrctinstallation.
Stp Stp
Stp2 2 2
Ensurthatthflowdirctioniscorrct.
A=Inlt
B=Outlt
Stp Stp
Stp3 3 3
Avoidstrssingthvalv.
Payspcialattntionto:
-Vibrations.
-Thrmalxpansionofthtubs.
-Excssivwlding.
-Ovrloadingofthpiplins.
9

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
Therequiredproductpressureispresetbymeansofanairpressureregulatingvalve(optionaletra).
Stp Stp
Stp4 4 4
Fittings: Fittings:
Fittings:
Ensurthatthconnctionsartight.
* *
*= = =Rmmbr Rmmbr Rmmbrsal sal salrings! rings! rings!
Stp Stp
Stp5 5 5
Air Air
Airconnction: connction: connction:
* *
*= = =R1/4 R1/4 R1/4" " "(BSP) (BSP) (BSP)
Stp Stp
Stp6 6 6
Air Air
Airpr pr prssur ssur ssur r r rgulating gulating gulatingvalv valv valv(optionalxtra):
Itisrcommnddtoinstallthairprssurrgulatingvalvas
closaspossibltothvalv.
* *
*= = =Pr Pr Prssur ssur ssur r r rgulating gulating gulatingvalv. valv. valv.Install Install Installas as asclos clos closas as aspossibl. possibl. possibl.
10

3Installation
Studytheinstructionscarefully.
Thevalvehasweldingendsasstandard.Weldcarefully.
3.3Welding
Stp Stp
Stp1 1 1
NOTE! NOTE!
NOTE!
Nvr Nvr
Nvrwldboththinltandoutltconnctions.Ifso,itwillbimpossibltosrvicthlowrvalvbodysalring(16)
Stp Stp
Stp2 2 2
W W
Wlding lding ldingth th thinlt inlt inltconnction connction connction
1.Wldthvalvbodyintothpiplins.
2.Maintainthminimumclarancsothatthintrnalvalvparts
canbrmovd.
A= A=
A=440 440 440mm mm mm(without (without (withoutboostr) boostr) boostr)/ / /540 540 540mm mm mm(with (with (withboostr) boostr) boostr)
Stp Stp
Stp3 3 3
W W
Wlding lding ldingth th thoutlt outlt outltconnction connction connction
Dismantlthvalvinaccordancwithsction5.2Dismantling,
Stp1andStp2.
11

3Installation
Studytheinstructionscarefully.
Thevalvehasweldingendsasstandard.Weldcarefully.
Stp Stp
Stp4 4 4
W W
Wlding lding ldingth th thoutlt outlt outltconnction connction connction:
1.Wldthlowrbody(10)intothpiplins.
2.Maintainthminimumclarancsothatthintrnalvalvparts
canbrmovd.
A A
A= = =284 284 284mm mm mm(without (without (withoutboostr) boostr) boostr)/ / /384 384 384mm mm mm(with (with (withboostr) boostr) boostr)
Stp Stp
Stp5 5 5
W W
Wlding lding ldingth th thoutlt outlt outltconnction connction connction:
Assmblthvalvinaccordancwithsction5.3Assmbly,
Stp11andStp12.
Stp Stp
Stp6 6 6
Pr Pr
Pr - - -us us uschck: chck: chck:
Liftandlowrthvalvtopsvraltimstonsurthatthvalv
opratssmoothly.
Pay Pay
Payspcial spcial spcialattntion attntion attntionto to toth th thwar war warning! ning! ning!
*=Liftandlowrbyhand!
12

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoincreasethepermittedproductpressure.
3.4FittingofBooster(optionalextra)
Stp Stp
Stp1 1 1
Nvr Nvr
Nvrtouchthvalvorthpiplinswhnprocssinghotliquids
orwhnstrilizing.
Th Th
Thvalv valv valvand and andth th thpiplins piplins piplinsmust must mustnvr nvr nvrb b bpr pr prssurisd ssurisd ssurisdwhn whn whn
dismantling dismantling
dismantlingth th thvalv. valv. valv.
Atmosphric Atmosphric
Atmosphricpr pr prssur ssur ssur r r rquir quir quird. d. d.
Stp Stp
Stp2 2 2
1.Rmovthvalvtopinaccordancwithsction5.2
Dismantling,Stp5.
Pay Pay
Payspcial spcial spcialattntion attntion attntionto to toth th thwar war warnings! nings! nings!
2.FitBoostrhousing(1)onthcovr.
3.Fitandtightnlocknut(2).
Stp Stp
Stp3 3 3
1.Fitwashr(3).
2.Rfitthwashrandthtopnutonthvalvplug.
13

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoincreasethepermittedproductpressure.
Stp Stp
Stp4 4 4
1.Turndiaphragm(7)insidout.
2.Placpiston(6)inthdiaphragmsothatthholisvisibl.
Stp Stp
Stp5 5 5
1.Rolldiaphragm(7)downhalfit’slnght.
2.Fitthdiaphragmwithpiston(6)inBoostrhousing(1).
Stp Stp
Stp6 6 6
1.Fitcovr(8)onBoostrhousing(1).
2.Fitandtightnclamp(9).
3.ThvalvandthBoostrarnowradyforopration.
14

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Theitemsrefertothepartslistandservicekitssection.
ThevalvecanbefittedwithaBoostertoincreasethepermittedproductpressure.
3.5Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmatrialconsistsofwood,plastics,cardboardboxsandinsomcassmtalstraps
-Woodandcardboardboxscanbrusd,rcycldorusdfornrgyrcovry
-Plasticsshouldbrcycldorburntatalicnsdwastincinrationplant
-Mtalstrapsshouldbsntformatrialrcycling
• •
•Maintnanc Maintnanc Maintnanc
-Duringmaintnancoilandwarpartsinthmachinarrplacd
-Allmtalpartsshouldbsntformatrialrcycling
-Wornoutordfctivlctronicpartsshouldbsnttoalicnsdhandlrformatrialrcycling
-Oilandallnonmtalwarpartsmustbtakncarofinagrmntwithlocalrgulations
• •
•Scrapping Scrapping Scrapping
-Atndofus,thquipmntshallbrcycldaccordingtorlvant,localrgulations.Bsidthquipmntitslf,any
hazardousrsidusfromthprocssliquidmustbconsidrdanddaltwithinaproprmannr.Whnindoubt,orinth
absncoflocalrgulations,plascontactthlocalAlfaLavalsalscompany
15

4Operation
Thevalveislubricated,adjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Operation
Stp Stp
Stp1 1 1
Always Always
Alwaysradthtchnicaldatathoroughly.
Always Always
Alwaysrlascomprssdairaftrus.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbhldrsponsiblforincorrct
opration.
Stp Stp
Stp2 2 2
Nvr Nvr
Nvrtouchthvalvorthpiplinswhnprocssinghotliquids
orwhnstrilizing.
Stp Stp
Stp3 3 3
Nvr Nvr
Nvrtouchthvalvtopifcomprssdairissupplidtoth
valv.
16

4Operation
Thevalveislubricated,adjustedandtestedbeforedelivery.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Stp Stp
Stp4 4 4
CAUTION! CAUTION!
CAUTION!
Thrmustnotbvacuuminthvalvasaircanbdrawninto
thproductanddiaphragms(17)canthnbpulldoutfrom
supportsctors(20).
* *
*= = =No No Novacuum! vacuum! vacuum!
Stp Stp
Stp5 5 5
Lubrication: Lubrication:
Lubrication:
1.Ensursmoothmovmntbtwndiaphragms(17,18)
andsupportsctors(20).
2.Ensursmoothmovmntofguid(5).
Lubricatifncssary!
(S5.1Gnralmaintnanc).
17

4Operation
Payattentiontopossiblebreak-down.
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
4.2Faultnding
NOTE! NOTE!
NOTE!
Studythmaintnancinstructionscarfullybforrplacingwornparts-schaptr5.1Gnralmaintnanc
Pr Pr
Problm oblm oblmCaus/r Caus/r
Caus/rsult sult sultRpair Rpair
Rpair
Thvalvdosnotmaintainthprst
prssur
FaultydiaphragmRplacthdiaphragm
Guid(9)sizsLubricatthguid(s4.1Opration,
Stp5)
IncorrctopratingrangChckthprssurdropovrthvalv
andchckthflowrat(schaptr
6.2Slction/Prssurdrop-capacity
diagram)
Thavailablairprssurislowrthan
thproductprssur
Incrasthairprssurg.byusing
aBoostr(schaptr3.4Fittingof
Boostr(optionalxtra)).
ThairprssurisnotcorrctlyadjustdRadjustthairprssur
Faultyairprssurrgulatingvalvor
incorrcttyp
Rpairthvalvorchckthatitis
prssurcompnsating
ProductlakagWorndiaphragmRplacthdiaphragm
Productaffctddiaphragm
AirlakagWornO-ringRplacthO-ring
Worndiaphragm(10)Rplacthdiaphragm
Wornandharddiaphragm(10)Rplacbyadiaphragmofadiffrnt
gradforhighrtmpratur(schaptr
6.1Tchnicaldata)
Valvplugmovingtoofastupanddown
(unstabl)
Prssurpulsationsbcausoffast
changsinprocssconditions
Usanairthrottlingvalv(optionalxtra
btwnthairprssurrgulatingvalv
andthCPM-I-D60valv.
18

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.HNO3=Nitricacid.
4.3Recommendedcleaning
Stp Stp
Stp1 1 1
Always Always
Alwayshandllyandacidwithgratcar.
Caustic Caustic
Causticdangr! dangr! dangr!
Always Always
Alwaysus
rubbrglovs!
Always Always
Alwaysus
protctivgoggls!
Stp Stp
Stp2 2 2
Nvr Nvr
Nvrtouchthvalvorthpiplinswhnstrilizing.
Stp Stp
Stp3 3 3
CPMI CPMI
CPMI- - -2 2 2
EnsurthatthvalvisfullyopntoallowformaximumCIPflow.
*=Noprssur
A=CIPin
B=CIPout
19

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.HNO3=Nitricacid.
Stp Stp
Stp4 4 4
Exampls Exampls
Examplsof of ofclaning claning claningagnts: agnts: agnts:
Usclanwatr,frfromclorids.
1.1%bywightNaOHat70oC(158oF)2.0.5%bywightHNO3at70oC(158oF)
1kg(2.2lbs)
NaOH+100l
(26.4gal)watr=Claningagnt.0.7l(0.2gal)
53%HNO3+100l
(26.4gal)watr=Claningagnt.
2.2l(0.6gal)
33%NaOH+100l
(26.4gal)watr=Claningagnt.
Stp Stp
Stp5 5 5
1.Avoidxcssivconcntrationofthclaningagnt.
-Dosgradually.
2.Adjustthclaningflowtothprocss.
-Strilizationofmilk/viscousliquids.
-Incrasthclaningflow.
3.Always Always
Alwaysrinswllwithclanwatraftrthclaning.
Stp Stp
Stp6 6 6
NOTE NOTE
NOTE
Thclaningagntsmustbstord/disposdofinaccordancwithcurrntruls/dirctivs.
20