Alfalaval RV-P User manual

ESE02801-EN52022-10
Originalmanual
InstructionManual
UniqueRV-P,pneumaticregulatingvalve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetprecautions................................................................................7
3.Installation....................................................................................9
3.1.Unpacking/deliver...............................................................................9
3.2.Generalinstallation................................................................................10
3.3.Welding............................................................................................12
3.4.Recclinginformation.............................................................................15
4.Operation.....................................................................................16
4.1.Operation..........................................................................................16
4.2.Troubleshooting...................................................................................18
4.3.Recommendedcleaning.........................................................................18
5.Maintenance..................................................................................20
5.1.Generalmaintenance.............................................................................20
5.2.Dismantlingthevalve.............................................................................22
5.3.Plugsealreplacement............................................................................24
5.4.Valveassembl....................................................................................24
6.Technicaldata................................................................................25
6.1.Technicaldata.....................................................................................25
7.Partslistandservicekits...................................................................27
7.1.Standardmodel...................................................................................27
7.2.Asepticmodel.....................................................................................31
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
UniqueRV-P ,UniqueRV-P-A
Tpe
isinconformitwiththefollowingdirectiveswithamendments:
-MachinerDirective2006/42/EC
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformitreplacesDeclarationofConformitdated2016-10-26
4

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

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
2.1Importantinformation
Alwas Alwas
Alwasreadthemanualbeforeusingthevalve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjur.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimpliforclarifprocedures.
ThisInstructionmanualisdesignedtoprovidetheuserwiththeinformationtoperformtaskssafelforallphasesinthelifetimeof
theproductsupplied.
Theusershallalwasreadthesafetsectionfirst.Hereaftertheusercanskiptotherelevantsectionforthetasktobecarried
outorfortheinformationneeded.
Thisisthecompletemanualforthesuppliedproduct.
Operators Operators
Operators
Theoperatorsshallreadandunderstandtheinstructionmanualforthesuppliedproduct.
Maintenance Maintenance
Maintenancepersonnel personnel personnel
Themaintenancepersonnelshallreadandunderstandtheinstructionmanual.
Themaintenancepersonnelortechniciansshallbeskilledwithinthefieldrequiredtocarroutthemaintenanceworksafel.
T T
Trainees rainees rainees
Traineescanperformtasksunderthesupervisionofanexperiencedemploee.
People People
Peoplein in ingeneral general general
Thepublicshallnothaveaccesstothesuppliedproduct.
How How
Howto to tocontact contact contactAlfa Alfa AlfaLaval Laval Laval
Contactdetailsforallcountriesare
continuallupdatedonourwebsite.
Pleasevisitwww.alfalaval.comtoaccesstheinformationdirectl.
2.2Warningsigns
Generalwarning:
Causticagents:
6

2Safety
Allwarningsinthismanualaresummarisedonthispage.
Payspecialattentiontothisinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seechapter6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Operation: Operation:
Operation:
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure
Never Never
Neverdismantlethevalvewhenitishot
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seechapter6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilising
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Alwas Alwas
Alwasrinsewellwithcleanwateraftercleaning
Alwas Alwas
Alwashandleleandacidwithgreatcare
Maintenance: Maintenance:
Maintenance:
Alwas Alwas
Alwasreadthetechnicaldatathoroughl(seechapter6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse
Never Never
Neverservicethevalvewhenitishot
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure
Never Never
Neverstickourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwithcompressedair
Alwas Alwas
AlwasuseAlfaLavalgenuinespareparts.ThewarrantofAlfaLavalproductsisdependentontheuseofAlfa
Lavalgenuinespareparts.
T T
Transportation: ransportation: ransportation:
Alwas Alwas
Alwasensurethatcompressedairisreleased
Alwas Alwas
Alwasensurethatallconnectionsaredisconnectedbeforeattemptingtoremovethevalvefromtheinstallation
Alwas Alwas
Alwasdrainliquidfromvalvesbeforetransportation
Alwas Alwas
Alwasusepredesignedliftingpointsifdefined
Alwas Alwas
Alwasensuresufficientfixingofthevalveduringtransportation-ifspecialldesignedpackagingmaterialisavailable,
itmustbeused
7

2Safety
Allwarningsinthismanualaresummarisedonthispage.
Payspecialattentiontothisinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
STORAGE STORAGE
STORAGE
Ideall,asaguideAlfaLavalrecommend:
-Storesuppliedproductassuppliedinoriginalpackaging
-Portopeningshouldbeprotectedagainstaningress
-Baresteel(notstainless)shouldbelightloiled/greased
-Storeinaclean,drplacewithoutdirectsunlightorUVlight
-Temperaturerange-5to40°C
-Relativehumiditlessthan60%
-Noexposuretocorrosivesubstances(alsoaircontained).
8

3Installation
Thisinstructionmanualispartofthedelivery.Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
Thevalveisassembledbeforedelivery.
3.1Unpacking/delivery
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
Alfa Alfa
AlfaLaval Laval Lavalcannot cannot cannotbe be beheld held heldr r responsible esponsible esponsiblefor for forincorr incorr incorrect ect ectunpacking. unpacking. unpacking.
Check Check
Checkthe the thedeliver deliver deliverfor: for: for:
1.Completevalve
2.Delivernote
3.Instructionmanual
Step Step
Step2 2 2
Removepossiblepackingmaterialsfromthevalve/valveparts.
Step Step
Step3 3 3
Inspectthevalveforvisibletransportdamage.
9

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
Step Step
Step4 4 4
Avoiddamagingtheairconnection,theelectricalconnectionand
thevalveports.
3.2Generalinstallation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Seechapter6Technicaldata.
Alwas Alwas
Alwasreleasecompressedairafteruse.
CAUTION CAUTION
CAUTION
Alfa Alfa
AlfaLaval Laval Lavalcannot cannot cannotbe be beheld held heldr r responsible esponsible esponsiblefor for forincorr incorr incorrect ect ect
installation. installation.
installation.
Step Step
Step2 2 2
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwith
compressedair.
Moving Moving
Movingparts! parts! parts!
10

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
Step Step
Step3 3 3
Toavoidwaterhammer,itisrecommendedtoinstallthevalveso
thattheflowisagainsttheclosingdirection.
Shockintheactuatormustnever never
neveroccur.
A A
Avoid void voidwater water waterhammer! hammer! hammer!
Outlet
Inlet
Step Step
Step4 4 4
Avoidstressingthevalve.
Pa Pa
Paspecial special specialattention attention attentionto: to: to:
-Vibrations.
-Thermalexpansionofthepipelines.
-Excessivewelding.
-Overloadingofthepipelines.
Risk Risk
Riskof of ofdamage! damage! damage!
11

3Installation
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
3.3Welding
Step Step
Step1 1 1
Alwas Alwas
Alwasweldthevalvebodintothesstemwhenitis
disassembledfromthevalve.
Maintaintheminimumclearance(A)sothattheactuatorcanbe
removed.
ValvesizeA(mm)
38mm/DN40100
51mm/DN50105
63.5mm/DN65130
76mm/DN80145
101.6mm/DN100180
12

3Installation
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
Step Step
Step2 2 2
Assemblethevalveinaccordancewiththestepsonpage24.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
Standar Standar
Standard d dmodel model model
1.LubricateO-ring(21)andlipseal(25)withAlfaLavalLubricant.
2.Fitseat(63)andO-ring(21)inthevalvebod(26).
3.Fitandtightenlowerclamp(19).
4.FitO-ring(21)andplug(23)invalvebod(26).
5.Fitbushing(24)andlipseal(25)inthebonnet(112).
6.Mounttheactuator(110)andbonnet(112)togetherwith
thevalvepartsinthevalvebod(26).
7.Fitandtightenupperclamp(19).
8.Fitandtightenvalveplugadjuster(114)andnut(115)
totheplug(23).
9.Fitandtightentheclampfittings(111).
13

3Installation
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
Aseptic Aseptic
Asepticmodel model model
1.LubricateO-ring(21)withAlfaLavalLubricant.
2.Fitseat(63)andO-ring(21)inthevalvebod(26).
3.Fitandtightenlowerclamp(19).
4.Fitplug(23)invalvebod(26).
5.Fitbushing(24)inthebonnet(112).
6.Mounttheactuator(110)andbonnet(112)togetherwith
thevalvepartsinthevalvebod(26).
7.Fitandtightenupperclamp(19).
8.Fitandtightenvalveplugadjuster(114)andnut(115)
totheplug(23).
9.Fitandtightentheclampfittings(111).
14

3Installation
Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
Checkthevalveforsmoothoperationafterwelding.
Step Step
Step3 3 3
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.Activatethevalveusingcompressedair.
2.Openandclosethevalveseveraltimestoensurethatit
operatessmoothl.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
3.4Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesand,insomecases,metalstraps
-Woodandcardboardboxescanbere-used,reccledorusedforenergrecover
-Plasticsshouldbereccledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialreccling
• •
•Maintenance Maintenance Maintenance
-Duringmaintenance,oilandwearingpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialreccling
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialreccling
-Oilandallnon-metalwearpartsmustbedisposedinaccordancewithlocalregulations
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentmustbereccledaccordingtotherelevantlocalregulations.Besidestheequipmentitself,
anhazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,or
intheabsenceoflocalregulations,pleasecontactourlocalAlfaLavalsalescompan
15

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
Ensurethatthevalveoperatessmoothly.
Theitemsrefertothepartslistandservicekitssection.
4.1Operation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Seechapter6Technicaldata.
Alwas Alwas
Alwasreleasecompressedairafteruse.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
operation.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghot
liquidsorwhensterilising.Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Never Never
Nevertouchmovingpartsiftheactuatorissuppliedwith
compressedair.
Moving Moving
Moving
parts! parts!
parts!
16

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
Ensurethatthevalveoperatessmoothly.
Theitemsrefertothepartslistandservicekitssection.
Step Step
Step4 4 4
Lubrication Lubrication
Lubricationof of ofvalves: valves: valves:
1.Ensuresmoothmovementbetweenlipseal(25)and
plugstem(23).
2.LubricatewithAlfaLavalLubricantifnecessar
(seesection5.1Generalmaintenance).
Step Step
Step5 5 5
Lubrication Lubrication
Lubricationof of ofactuator actuator actuator
1.Ensuresmoothmovementoftheactuator(theactuatoris
lubricatedbeforedeliver).
2.LubricatewithMolkoteLongterm2plusifnecessar.
17

4Operation
Payattentiontopossiblefaults.Studytheinstructionscarefully.
Theitemsrefertothepartslistandservicekitssection.
4.2Troubleshooting
NOTE! NOTE!
NOTE!
Studthemaintenanceinstructionscarefullbeforereplacingwornparts-section5.1Generalmaintenance.
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRepair Repair
Repair
ExternalproductleakageWornordamagedlip
sealand/orO-ring
-Replacetheseals
-Replacewithsealsofa
differentrubbergrade
Internalproductleakage-Wornorproduct-affected
plugseal-Replacetheseal -Replacewithasealofa
differentrubbergrade
-Productdepositson
theseatand/orplug-Frequentcleaning
WaterhammerTheflowdirectionisthe
sameastheclosingdirection
-Theflowdirectionshouldbe
againsttheclosingdirection
-Throttleairreleaseofsolenoidin
topunit
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
Nevertouchthevalveorthepipelineswhensterilising.Danger Danger
Dangerof of ofbur bur burns! ns! ns!
18

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
NaOH=Causticsoda.
HNO3=Nitricacid.
Step Step
Step3 3 3
Cleantheplugandtheseatscorrectl.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings nings nings
Lift Lift
Liftand and andlower lower lowervalve valve valveplug plug plugmomentaril! momentaril! momentaril!
Step Step
Step4 4 4
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents: agents: agents:
Usecleanwater,freefromchlorides.
1.1%bweightNaOHat70oC2.0.5%bweightHNO3at70oC
1kg
NaOH+100l water=Cleaningagent.0.7l 53%HNO3+100l water=Cleaningagent.
2.2l
33%NaOH+100l water=Cleaningagent.
Step Step
Step5 5 5
1.Avoidexcessiveconcentrationofthecleaningagent.
2.Adjustthecleaningflowtotheprocess.
3.Alwas Alwas
Alwasrinsewellwithcleanwateraftercleaning.
NOTE NOTE
NOTE
Thecleaningagentsmustbestored/disposedofinaccordance
withcurrentregulations/directives.
Alwas Alwas
Alwasrinse! rinse! rinse!
CleanwaterCleaningagents
19

5Maintenance
Maintainthevalveregularly.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings
Alwayskeepsparerubbersealsandlipsealsinstock.AlwaysuseAlfaLavalgenuinespareparts.
Checkthevalveforsmoothoperationafterservice.
5.1Generalmaintenance
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
Seechapter6Technicaldata
Alwas Alwas
Alwasreleasecompressedairafteruse.
NOTE NOTE
NOTE
Allscrapmustbestored/dischargedinaccordance
withcurrentregulations/directives.
Step Step
Step2 2 2
Never Never
Neverservicethevalvewhenitishot.
Never Never
Neverservicethevalvewithvalveandpipelinesunderpressure.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Never Never
Neverstickourfingersthroughthevalveportsiftheactuatoris
suppliedwithcompressedair.
Danger Danger
Dangerof of ofcuts! cuts! cuts!
20