SPX APV DELTA DKRT2 User manual

Read and understand this manual prior to
operating or servicing this product.
Operating Manual
DELTA DKRT2
Double - Seat Ball Valve with Cleaning Connection
Tank Outlet Valve

1
UK
1. General Terms 2
2. Safety Instructions 2
3. Mode of Operation 3
4. Auxiliary Equipment 4 - 5
5. Cleaning 5
6. Installation 5
6.1 Welding Instructions 6
7. Materials 6
8. Dimensions / Weights 7
9. Technical Data 8
10. Maintenance 8
11. Service Instructions 9 - 12
12. Detection of Seal Damage 13
13. Spare Parts Lists
DKRT - DN50, 80, 100 RN - 01.078
Table of Contents : Page :
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

This operating manual should be read carefully by the competent
operating and maintenance personnel.
We point out that we will not accept any liability for damage or
malfunctions resulting from the non-compliance with this
operating manual.
Descriptions and data given herein are subject to technical changes.
2. Safety Instructions
Danger!
- The line and cleaning system must be depressurized before any
maintenance of the valve.
- Electric and pneumatic connections must be separated.
-Do not reach into the open valve ball!
Risk of injury by sudden valve operation!
- Observe service instructions to ensure a safe maintenance of
the valve.
- Dismantle the actuator before the exchange of seals.
- During valve operation, operating leakages spirt out the drain
pipe to the bottom.
- If the cleaning connection is not used, it must be sealed by a
plug or operating leakages must be discharged.
1. General Terms
2
UK
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

3. Mode of operation
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UK
The DKRT 2 double-seat ball valve was particularly developed for
the use in applications in which product safety against intermixing
is of highest priority.
Low tank outlet heights through compact constructions, unreduced
flow capacities through pipe diameter - sized balls and double-seal
technology guarantee a safe and product-gentle function.
- Actuation of the pneumatic turning actuator with air connection at
(A) drives the valve into the position "open". Reset into the limit
position "closed" by spring force.
- In closed position two line sections with different liquids (B and C)
are separated by two independently acting seals.
The intervening leakage chamber is open to the atmosphere
through the free drain (D).
- In open position the liquid flows through the free opening cross
section of the smooth valve passage. No inversion of the liquid
flow in the valve area.
- In closed and open operating position cleaning liquid can be
injected at the CIP connection at (E) to clean the leakage chamber.
- During the operating process, operating leakages bleed from the
leakage drain (D) downwards. If a cleaning line is not connected,
the cleaning connection (E) must be sealed by a plug or operating
leakages must be discharged.
- The cleaning connection (E) can be used to vent the leakage
chamber for a faster emptying or to sterilize the leakage chamber
with steam.
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

4
4. Auxiliary Equipment
UK
Valve position indication
- Switches to signal the limit position of the valve ball can be
installed in the yoke if requested.
We recommend our APV standard proximity switches.
Type: three-wire proximity switch
(ref.-No. 08-60-011/93)
Operating distance: 4 mm / diameter : 11 mm / length: 30 mm
Feedback complete with support and proximity switch
(ref.-No. 15-33-023/93) for a limit position.
If the user decides to apply valve position indicators other than
APV type, we cannot take over the liability for any malfunctions
resulting therefrom.
- Control Unit
Units with feedback switches and solenoid valves to be assembled
on the actuator, for the pneumatic control of the valve are also
available in fieldbus technology.
The Control Unit CU3 can be installed on the turning actuator.
Different types are available:
- For the installation of a control unit on the DKR2 valve a special
turning actuator and an adapter are required.
The standard actuator must be replaced.
designation : ref.-No.:
CU 31 Direct Connect 322 000 804 629
CU 21 Profibus 322 000 804 437
CU 31 Device Net 322 000 804 611
CU 31 AS - Interface 322 000 804 701
turning actuators and corresponding adapters
for control units
ref.-No.:
turning actuator K 080 000 - 15 - 37 - 070/17
DN 50
adapter
CU 2 adapter SV1 / SVS1F / DKR2 322 000 801 194
turning actuator K 125 000 - 15 - 37 - 106/17
DN 80 - 100
adapter
CU 2 adapter SV1 / SVS1F / DKR2 322 000 801 195
turning actuator for
Control - Unit
control unit
with adapter
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

5
4. Auxiliary Equipment
UK
The tank bottom welding flange for the DKRT2 valve
does not form part of the scope of supply.
Order reference numbers for the tank bottom welding flange:
5. Cleaning
Cleaning recommendation for the DKR valve
in the beverage industry
- The flushing times refer to a cleaning pressure of p = 3 - 5 bar.
- The flushing times indicated for the individual cleaning steps are
standard values. In specific applications these times must be
adjusted depending on the product, the pressure ratio and the
degree of soiling.
- The flushing quantity per CIP spraying cycle amounts to
about 1 litre at a cleaning pressure of 3 - 5 bar.
6. Installation
- The valve must be installed in horizontal position at the tank bottom.
Fluids and operating leakages are, therefore, freely drainable to the
bottom and the leakage chamber drains off.
- With several valves being parallely connected with one pipeline,
a passage of the operating leakage to the cleaning connection of
adjacent valves must be avoided.
Installation of a shut-off device or a check valve in front of the
cleaning connection is required.
- Cleaning connection with hose 8 x 1.
-Attention: Observe welding instructions.
cleaning step CIP - spraying
pre - flushing 2 x 10 sec.
caustic flushing 80° C 3 x 10 sec.
intermediate flushing 2 x 10 sec.
acid flushing 3 x 10 sec.
subsequent flushing 2 x 10 sec.
tank bottom welding flange
C
M10
DN ref.-No.:
50 31B 31 - 08 - 030/47
80 31B 31 - 08 - 032/47
100 31B 31 - 08 - 034/47
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

6
UK
6.1 Welding Instructions
DKRT
- Before welding of the valve, the welding flanges must be dismantled
from the housing. Tacking or adjustment of the valves should only
be undertaken with screwed down welding flanges.
- The welding of the mating flanges must be undertaken in such a
way that deformation does not occur.
- Welding should only be carried out by certified welders (EN 287-1).
(Seam quality EN 25817 "B").
- TIG orbital welding is best!
- The preparation of the weld seam up to 3 mm thickness can be
carried out as a square butt joint without air. (Consider shrinkage!)
- After welding of the mating flanges and after work at the pipelines,
the corresponding parts of the installation or pipelines must be
cleaned from welding residues and soiling. If these cleaning
instructions are not observed, welding residues and dirt particles
can settle in the valve and cause damage or can be transfered to
other parts of the installation.
- Any damage resulting from the non-observance of these welding
instructions is not subject to our guarantee.
7. Materials
- housing, valve ball, shafts 1.4404
- yoke, actuator 1.4301
- coupling 1.4057
- ball seal PTFE
- housing seal EPDM, FPM
- flange seal EPDM, FPM
- O-rings EPDM
- indicator PE-solid
plastic parts in actuator
- spindle bearing Vestamid L 1901
- air connection PA 6.6
- piston Hostaform C 9021
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

7
UK
AB
D
E
FF
A1 G1/8
A A1 B D E F weight
in kg
DN
50 427 563 75 50,0 79,0 85 6,0
80 543 678 102,5 81,0 123,0 130 16,0
100 574 707 117 100,0 150,0 130 19,0
Dimensions in mm
DKRT 2 with Control Unit CU3
DKRT 2 with actuator
8. Dimensions and Weights
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

8
UK
DN 50 80 100
max. tightening torque in Nm ( M ) 22 40 65
operating leakage at about
5 bar in L ( Qs) 1,4 4,0 4,2
( opening and closing operation )
pneumatic air consumption
at 6 bar in NL ( V ) 1,8 5,5 5,5
9. Technical Data
- max. line pressure : 10 bar
- max. operating temperature : 135oC EPDM, HNBR
*FPM, *VMQ
- short-term load : 140oC EPDM, HNBR
*FPM, *VMQ
* no steam
- throughput cleaning
at 3 bar admission pressure : about 5 - 10 l/min.
-actuator
max. control pressure : 10 bar
min. control pressure : 6 bar
turning angle : 90o
- leakage connection : G1/8
- cleaning connection (for hose ) : 8 x 1mm
- air connection (for hose) : 6 x 1mm
(Use dry and clean air, only.)
10. Maintenance
- Dismantling and installation of seals according to service
instructions.
- Assembly and adjustment of turning actuator according to
service instructions.
- Slightly grease all seals.
Recommendation:
APV food-grade-grease for EPDM and FPM
(750 g/tin - ref.-No. 000 70-01-019/93)
(60 g/tube - ref.-No. 000 70-01-018/93)
or
APV food-grade-grease for VMQ and Perbunan
(600 g/tin - ref.-No. 000 70-01-017/93)
(60 g/tube - ref.-No. 000 70-01-016/93)
! Do not use grease containing mineral oil with EPDM seals !
! Do not use Silicone-based grease with VMQ seals !
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

The item numbers refer to the spare parts drawing
(DIN design: RN 01.078)
11.1 Dismantling from the line system
a. Shut off connecting lines, lower line pressure and discharge
if possible.
b. Disconnect pneumatic and electric connections
c. Dismantle cleaning line.
d. Screw off valve position indicator.
e. Remove flange screws.
f. Detach ball valve from the flanges.
11.2 Dismantling of seals and guide bands
a. Detach flange seals (8).
b. Take off turning actuator (15) after removal of screws (16).
c. Release screws (18) and yoke (17), coupling (14), indicator (13)
and spray connection (10).
Danger! Do not replace seals before removal of turning
actuator from the valve.
d. Pull out PTFE ball seals (9) with appertaining housing seals (7).
To pull the ball seals out, half open the ball by hand and
grasp alternately behind the seal!
Attention! Ball and ball seal are sensitive to mechanical
damage, the surfaces must not be touched by tools.
e. Having released the screws (3), pull both shaft bearings (2) out of
the housing and replace O-rings (5) and (6) and guide bands (4).
Attention! With dismantled shaft bearings and seals, the
housing with ball must not be subject to vibrations.
9
UK
11. Service Instructions
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

11.3 Installation of seals and guide bands
a. Slightly grease O-rings (5, 6) and guide bands (4) before their
installation in the shaft bearings (2).
b. Push upper and lower shaft bearing (2) with a little grease in the
housing, insert screws (3), but do not tighten them.
c. Slightly grease housing seals (7) before their installation on the
PTFE ball seals (9).
d. Turn valve ball into open position by hand and install ball seals
with a little grease at both sides.
e. Slightly grease O-rings (12) and insert them in the spray
connection (10).
11.4 Assembly of valve
a. To ensure a safe handling of the valve, clamp the lower
bearing flange into a vice with protective cheeks. Turn the ball
into "open position".
Place yoke (17), spray connection (10), indicator (13) and
coupling (14) on the ball housing.The lower coupling cam must
point to the lower yoke bore (x) and the indicator must point
into flow direction.
b. Screw in screws (18), but do not tighten them.
10
UK
11. Service Instructions
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

11
UK
11.5 Adjustment of operating position
Attention! For a safe, perfect and fast adjustment of the
operating position, we recommend to use two
separate FG flanges.
11.5.1 Adjustment of operating position with FG flanges
(flanges see RN 268.22-1)
Install the ball seals as described in 11.3. Assemble the valve as
described in 11.4.
Turn the ball into its exact open position.
a. Control actuator (15) with pneumatic air (min. 6 bar) and place
it on the yoke (17).
b. Screw in screws item 16, but do not tigthen them.
Danger! Do not reach into the open valve after installation
of the actuator. Risk of injury by sudden operation
of the valve.
c. Screw down FG flanges at the housing. The ball must be in
its exact open position during this procedure.
d. Release both screws item 3of the shaft bearing (ball centers
between the seals) and retighten them.
e. Slightly turn the actuator in anticlockwise direction to adjust the
play in the connecting parts.
!!! The ball must keep its exact open position during this procedure !!!
Danger! Do not reach into the open valve.
Risk of injury by sudden operation of the valve.
f. At first, tighten the screws item 18 and then item 16. Operate the
turning actuator several times to check the operating accuracy
of the ball.
g. Shut off the air supply to the turning actuator and dismantle
the FG flanges.
h. Insert the valve in closed position between the flanges into the
pipeline and fasten it with the screws.
Tightening torque: M8 Md = 16 Nm
M10 Md = 40 Nm.
i. Connect pneumatic air line with turning actuator.
j. Connect cleaning line.
k. Attach valve position indicators.
11. Service Instructions
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

12
UK
11.5.2 Adjustment of operating position without FG flanges
If FG flanges are not available, the ball can, in exceptional cases,
be adjusted as follows.
(Attention! Failure of adjustement is possible.):
Install the ball seals as described in 11.3. Assemble the valve
as described in 11.4. Turn the ball into its exact open position.
a. Control actuator (15) with pneumatic air (min. 6 bar) and place
it on the yoke (17).
b. Screw in screws item 16, but do not tigthen them.
Danger! Do not reach into the open valve after installation
of the actuator. Risk of injury by sudden operation
of the valve.
! The ball must be in its exact open position !
c. Slightly turn the actuator in anticlockwise direction to adjust the
play in the connecting parts.
!!! The ball must not move during this procedure!!!
(exact open position)
At first, tighten the screws item 18 and then item 16. Operate the
turning actuator several times to check the operating accuracy
of the ball.
d. Shut off the air supply to the turning actuator and insert the valve
in closed position into the line system. Fasten it with the screws.
e. Centering of ball (absolutely necessary)
To center the ball between the seal rings, proceed as follows:
1. Release screws item 3 by about ¼ turn.
2. Release one screw item 18 by about ¼ turn.
3. Release second screw item 18 by about ¼ turn and retighten
it immediately.
Attention! Hold the turning actuator fast during this process.
Bring up holding moment in clockwise direction
(top view of actuator).
4. Tighten screw 18 and, then, screw 3.
f. Tightening torque: Md = 16 Nm M8
Md = 40 Nm M10
g. Connect pneumatic air line with turning actuator.
h. Connect cleaning line.
i. Attach valve position indicators.
11. Service Instructions
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

13
UK
12. Detection of Seal Wear
The replacement of seals is undertaken as described
in the Service Instructions 11.
Valve is closed and pressure from the valve ball
- Leakage at upper and lower housing flange
replace seal (8).
- Leakage at the leakage bore
replace seals (8, 9, 7).
Valve is closed and leakage during cleaning
via the spray connection
- Leakage at spray connection
replace O-rings (12).
- Leakage at shaft bearing
replace seals (4, 5, 6).
Valve is open
- Leakage at the leakage bore
replace seals (8, 9, 7).
If damaged seals are replaced, generally all seals should be
changed. Set of seals for the valve service are available.
The corresponding part numbers can be drawn from the
spare parts lists.
13. Spare Parts Lists
(see annex)
Double - Seat Ball Valve DELTA DKRT 2
Tank Outlet Valve
Operating Manual : Rev. 4

Your local contact:
APV
Zechenstraße 49
D-59425 Unna
Phone: [phone] Fax: [phone] / 108-210
For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.
Copyright © 2008 SPX Corporation
The information contained in this document, including any specifications and other product details, are subject to change without notice.
While we have taken care to ensure the information is accurate at the time of going to press, we assume no responsibility for errors or
omissions nor for any damages resulting from the use of the information contained herein.
UK
Translation of original manual
BA DKRT2 00002
ID-No.: H170758
rev. 4