Alfa Laval Unique SSV Instructions

Instruction Manual

Unique Single Seat Valve - Manually Operated

ESE00523-EN7

Original manual

2020-02

TD 461-583

TD 461-791

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. Welding .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

9

3.4. Recycling information . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

9

4.

Operation .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

10

4.1. Operation .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

10

4.2. Troubleshooting . . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

12

4.3. Recommended cleaning .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

13

5.

Maintenance . .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

15

5.1. General maintenance . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

15

5.2. Dismantling the valve . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

17

5.3. Plug seal replacement .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

17

5.4. Valve assembly .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

18

6.

Technical data . . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

19

6.1. Technical data . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

19

7.

Parts list and service kits .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

20

7.1. Drawing .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . .. .. . .. . .. .. . .. . .. . ..

20

7.2. Unique Single Seat Valve - Manual Operated Shut-off Valve . .. .. . .. . .. .. . .. . .. . .. .. . .. . .. . ..

21

7.3. Unique Single Seat Valve - Manual Operated Change-over Valve .. . .. .. . .. . .. . .. .. . .. . .. . ..

23

3

1 EC Declaration of Conformity

Revision of Declaration of Conformity: 29/12-09

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00

Phone No.

hereby declare that

Unique Single Seat Valve

Designation

Manually Operated

Type is in conformity with the following directives:

- Machinery Directive 2006/42/EC

- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A

The person authorised to compile the technical file is the signer of this document

Global Product Quality Manager

Pumps, Valves, Fittings and Tank Equipment

Title

Lars Kruse Andersen

Name

Kolding

Place

2016-06-01

Date Signature

4

Unsafe practices and other important information are emphasised in this manual.

Warnings are emphasised 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:

2 Safety

5

6

2 Safety

All warnings in this manual are summarised on this page.

Pay special attention to this 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 thoroughly (see chapter 6 Technical data)

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 dismantle the valve when it is hot

Always read the technical data thoroughly (see chapter 6 Technical data)

Never touch moving parts if the actuator is supplied with compressed air

Always rinse well with clean water after cleaning

Always handle lye and acid with great care

!

Maintenance:

Always read the technical data thoroughly (see chapter 6 Technical data)

Never service the valve when it is hot

Never service the valve with valve and pipelines under pressure

Transportation:

Always ensure that compressed air is released

Always ensure that all connections are disconnected before attempting to remove the valve from the installation

Always drain liquid out of valves before transportation

Always used predesigned lifting points if defined

Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available it must be used

!

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 (for welding).

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.

Step 2

Check the delivery for:

1. Complete valve, shut-off valve or change-over valve.

2. Delivery note.

2a

Shut-off valve:

1. Complete handle.

2. Bonnet (20).

3. Clamp (19).

4. Valve plug (23).

5. Valve body (22).

TD 461-585

2b

Change-over valve:

1. Complete actuator.

2. Bonnet (20).

3. 2 x clamps (19).

4. Valve plug (27).

5. Lower valve body (22).

6. Valve seat (28).

7. Upper valve body (26).

UP

Step 3

Remove possible packing materials from the valve/valve parts.

Inspect the valve/valve parts for visible transport damage.

Avoid damaging the valve/valve parts.

TD 461-586_1

7

3 Installation

Study the instructions carefully and pay special attention to the warnings!

The valve has welding ends as standard but can also be supplied with fittings.

3.2

General installation

Step 1

Always read the technical data carefully.

See chapter 6 Technical data.

CAUTION

Alfa Laval cannot be held responsible for incorrect installation.

Step 2

Never touch moving parts during operation.

Moving parts!

Step 3

It is recommended to install the valve so that the flow is against the closing direction to avoid water hammering.

Step 4

Avoid stressing the valve.

Pay special attention to:

Vibrations.

Thermal expansion of the pipelines.

Excessive welding.

Overloading of the pipelines.

TD 461-589

Avoid water hammering!

TD 461-590

Inlet

Inlet

Risk of damage!

TD 461-591

8

3 Installation

Study the instructions carefully.

The valve is supplied as separate parts to facilitate the welding.

The items refer to the parts list and service kits section.

Check the valve for smooth operation after welding.

3.3

Welding

Step 1

Always install valves with more than one valve body so that the seals between the valve bodies can be replaced. Do not weld more than one valve body into the system.

Measurement A is depending on body combination and piping solution.

It is recommended to fit sufficient clamps/unions to be able to disassemble the valve for servicing

Please see actual PD-sheet for further information.

Step 2

Assemble the valve in accordance with the steps on page 18.

Pay special attention to the warnings!

TD 461-592_1

TD 461-614

TD 461-593

Step 3

Pre-use check:

Open and close the valve several times to ensure that it operates smoothly.

Pay special attention to the warnings!

TD 461-594

3.4

Recycling information

• Unpacking

Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps

Wood and cardboard boxes can be re-used, recycled or used for energy recovery

Plastics should be recycled or burnt at a licensed waste incineration plant

Metal straps should be sent for material recycling

• Maintenance

During maintenance, oil and wearing parts in the machine are replaced

All metal parts should be sent for material recycling

Worn out or defective electronic parts should be sent to a licensed handler for material recycling

Oil and all non-metal wear parts must be disposed off in agreement with local regulations

• Scrapping

At end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company

9

4 Operation

Study the instructions carefully and pay special attention to the warnings!

Ensure that the valve operates smoothly.

The items refer to the parts list and service kits section.

4.1

Operation

Step 1

Always read the technical data carefully.

See chapter 6 Technical data.

CAUTION

Alfa Laval cannot be held responsible for incorrect operation.

Step 2

Never touch the valve or the pipelines when processing hot liquids or when sterilising.

Burn hazard!

TD 461-595

Step 3

Never touch moving parts during operation.

Step 4

Lubrication of valves:

1. Ensure smooth movement between lip seal (25) and plug stem (23, 27).

2. Lubricate the lip seal with Klüber Paraliq GTE 703 if necessary

(see page 15).

Moving parts!

Shut-off valve

TD 461-589

Change-over valve

TD 461-597

TD 461-615

10

Study the instructions carefully and pay special attention to the warnings!

Ensure that the valve operates smoothly.

The items refer to the parts list and service kits section.

Step 5

Lubrication of actuator

1. Ensure smooth movement of the crank mechanism (the cranck is lubricated before delivery).

2. Lubricate all seals with Molykote Longterm 2 plus if necessary.

4 Operation

TD 461-598

11

4 Operation

Pay attention to possible faults. Study the instructions carefully.

The items refer to the parts list and service kits section.

4.2

Troubleshooting

NOTE!

Study the maintenance instructions carefully before replacing worn parts - see page 15!

Problem Cause/result Repair

External product leakage Worn or product affected lip seal and/or O-ring

Replace the seals

Replace with seals of a different rubber grade

Internal product leakage

Water hammer

The valve does not open/close

Worn or product affected plug seal

Product deposits on the seat and/or plug

Product pressure exceeds actuator specification

The flow direction is the same as the closing direction

Product pressure exceeds actuator specification

Replace the seal

Replace with a seal of a different rubber grade

Frequent cleaning

Replace with a high pressure actuator

Use auxiliary air on the spring side

Reduce product pressure

The flow direction should be against the closing direction

Reduce product pressure

12

4 Operation

The valve is designed for cleaning in place (CIP).

Study the instructions carefully and pay special attention to the warnings!

NaOH = Caustic Soda.

HNO

3

= Nitric acid.

4.3

Recommended cleaning

Step 1

Always handle lye and acid with great care.

Step 2

Never touch the valve or the pipelines when sterilising.

Step 3

Clean the plug and the seats correctly.

Pay special attention to the warnings!

Lift and lower valve plug momentarily!

Step 4

Examples of cleaning agents:

Use clean water, free from chlorides.

Caustic danger!

Always use rubber gloves!

Always use protective goggles!

Burn hazard!

Shut-off valve

TD 461-595

Change-over valve

TD 461-599

Lift lower valve plug

TD 461-600

1. 1% by weight NaOH at 70 o C

1 kg NaOH + 100 l water = Cleaning agent.

2.2 l

33% NaOH

+

100 l water

= Cleaning agent.

2. 0.5% by weight HNO

3 at 70 o C

0.7 l

53% HNO

3

+

100 l water

= Cleaning agent.

13

4 Operation

The valve is designed for cleaning in place (CIP).

Study the instructions carefully and pay special attention to the warnings!

NaOH = Caustic Soda.

HNO

3

= Nitric acid.

Step 5

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.

Step 6

NOTE

The cleaning agents must be stored/disposed off in accordance with current regulations/directives.

Always rinse!

Clean water Cleaning agents

14

5 Maintenance

Maintain the valve regularly.

Study the instructions carefully and pay special attention to the warnings!

Always keep spare rubber seals and lip seals in stock.

5.1

General maintenance

Step 1

Always read the technical data carefully.

See chapter 6 Technical data.

Step 2

Never service the valve when it is hot.

NOTE

All scrap must be stored/discharged in accordance with current rules/directives.

Atmospheric pressure required!

Never service the valve with valve and pipelines under pressure.

Burn hazard!

TD 461-602

Step 3

!

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.

Moving parts!

Cutting hazard!

TD 461-589

15

5 Maintenance

Maintain the valve regularly.

Study the instructions carefully and pay special attention to the warnings!

Always keep spare rubber seals and lip seals in stock.

Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal working conditions in one shift.

Product wetted seals

Preventive maintenance

Maintenance after leakage (leakage normally starts slowly)

Replace after 12 months depending on working conditions

Replace at the end of the day

Planned maintenance

Lubrication

Regular inspection for leakage and smooth operation

Keep a record of the valve

Use the statistics for inspection planning

Replace after leakage

Before fitting

Klüber Paraliq GTE 703 or similar USDA H1 approved oil/grease

Pre-use check:

Open and close the valve several times to ensure that it operates smoothly.

Pay special attention to the warnings!

TD 461-589

Recommended spare parts

Service kits (see page 20)

16

5 Maintenance

Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.

5.2

Dismantling the valve

Step 1

1a

Shut-off valve:

1. Remove cap, loosen screw and remove the washer by sliding it sideways.

2. Loosen and remove clamp.

3. Lift away the crank.

4. Remove valve plug.

5. Remove O-ring, lip seal and bushing in bonnet.

(Use bushing tool and rubber mallet).

Note! Be careful not to damage the bushing.

Pay special attention to the warnings!

Note! For plug seal replacement please see 17.

TD 461-959

1b

Change-over valve:

1. Loosen and remove lower clamp.

2. Lift away the crank and upper valve body.

3. Remove cap, loosen screw and remove the washer by sliding it sideways.

4. Loosen and remove upper clamp.

5. Lift away the crank.

6. Remove valve body.

7. Remove seat and O-rings.

8. Remove O-ring, lip seal and bushing in bonnet.

(Use bushing tool and rubber mallet.

See drawing, step 1a).

Note! Be careful not to damage the bushing.

Pay special attention to the warnings!

Note! For plug seal replacement please see 17.

5.3

Plug seal replacement

1. Remove old seal ring using a knife, screwdriver or similar.

Be careful not to damage metal parts.

2. Pre-mount plug seal without pressing it into the groove.

3. Squeeze plug seal into the groove using opposite pressure points.

4. Release compressed air behind plug seal.

Note! For plug seal replacement please read instruction in service kit.

UP

TD 461-601

TD 461-607_1

17

5 Maintenance

Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.

5.4

Valve assembly

Reverse order of 5.2 Dismantling the valve.

Lubricate O-ring (21) and lip seal (25) with Klüber Paraliq GTE 703.

Remember to tighten spindle and plug to a torque of 30Nm. (to use two 17mm spanners)

If there are vibrations in the pipeline Alfa Laval recommended using loctite no. 243.

The clamps thread must be lubricated before tightening - max. torque for the clamps is 10-12 Nm.

Note! Do not forget to screw in lower set screw (7) when assembling the valve.

It acts as a stroke stop. Without this screw the valve can be opened so far that the crank comes off.

In some valve sizes the flats on the plug stem may enter into the lip seal, which will then leak.

18

6 Technical data

It is important to observe the technical data during installation, operation and maintenance.

Inform all personnel about the technical data.

6.1

Technical data

Data - valve

Max. product pressure

Min. product pressure

Temperature range

Materials - valve/crank mechanism

Product wetted steel parts

Other steel parts

Plug seal

Other product wetted seals

Optional product wetted seals

1000 kPa (10 bar).

Full vacuum (depending on product specifications).

-10 o C to + 140 o C (standard EPDM seal).

1.4404 (316L) (internal Ra < 0.8 µm).

1.4301 (304).

EPDM / PTFE (TR2).

EPDM (standard).

HNBR and FPM.

Noise

One metre away from and 1.6 metres above the exhaust the noise level of a valve actuator will be approximately 77db (A) without noise damper and approximately 72 db (A) with damper - measured at 7 bar air-pressure.

19

7 Parts list and service kits

The drawing shows Unique Single Seat Valve - Manually operated.

The items refer to the parts list in the following sections

7.1

Drawing

Shut-off

TD 461-666

TD 461-667

Change-over

20

7 Parts list and service kits

The drawing shows Unique Single Seat Valve - Manual operated, Shut-off.

The items refer to the parts lists in the following sections

7.2

Unique Single Seat Valve - Manual Operated Shut-off Valve

8

6

TD 461-450_2

21

7 Parts list and service kits

The drawing shows Unique Single Seat Valve - Manual operated, Shut-off.

The items refer to the parts lists in the following sections

Parts list

Pos.

1

2

3

4

6

7

8

19

20

21 

22

23

23.1

23.2



24

25 

Service kits

1

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

Qty Denomination

Crank mechanism complete

O-ring set (10 pcs.) EPDM

O-ring set (10 pcs.) HNBR

O-ring set (10 pcs.) FPM

Lip seal set (10 pcs.) EPDM

Lip seal set (10 pcs.) HNBR

Lip seal set (10 pcs.) FPM

Plug seat set (10 pcs.) EPDM

Plug seal set (10 pcs.) HNBR

Plug seat set (10 pcs.) FPM

Crank

Handle (included in pos. 1 )

Cap

Washer

Guide

Set screw

Stem holder

Clamp

Bonnet

O-ring

Valve body

Plug

Plug

Plug seal

Bushing

Lip seal

Denomination

DN 25

25 mm

DN 40

38 mm

DN 50

51 mm

DN 65

63.5 mm

DN 80

76.1 mm

DN 100

101.6 mm

Service kit for product wetted parts, standard

 Service kit, EPDM . . . . . . . . . .

9611926501 9611926502 9611926503 9611926504 9611926505 9611926506

 Service kit, HNBR . . . . . . . . . .

9611926507 9611926508 9611926509 9611926510 9611926511 9611926512

 Service kit, FPM . . . . . . . . . . . .

9611926513 9611926514 9611926515 9611926516 9611926517 9611926518

Parts marked with  are included in the service kits (product wetted parts)

Recommended spare parts: Service kits.

TD 900-383/2

22

The drawing shows Unique Single Seat Valve - Manual operated, Change-over.

The items refer to the parts lists in the following sections

7 Parts list and service kits

7.3

Unique Single Seat Valve - Manual Operated Change-over Valve

TD 461-449_1

23

7 Parts list and service kits

The drawing shows Unique Single Seat Valve - Manual operated, Change-over.

The items refer to the parts lists in the following sections

Parts list

Pos.

1

2

3

4

6

7

8

19

20

21 

22

24

25 

26

27

27.1

27.2



28

Service kits

1

1

2

1

2

1

3

1

1

1

1

1

1

1

2

1

1

1

Qty Denomination

Crank mechanism complete

O-ring set (10 pcs.) EPDM

O-ring set (10 pcs.) HNBR

O-ring set (10 pcs.) FPM

Lip seal set (10 pcs.) EPDM

Lip seal set (10 pcs.) HNBR

Lip seal set (10 pcs.) FPM

Plug seal set (10 pcs.) EPDM

Plug seal set (10 pcs.) HNBR

Plug seal set (10 pcs.) FPM

Crank

Handle (included in pos. 1 )

Cap

Washer

Guide

Set screw

Stem holder

Clamp

Bonnet

O-ring

Valve body

Bushing

Lip seal

Valve body

Plug

Plug

Plug seal

Seat

Denomination

DN 25

25 mm

DN 40

38 mm

DN 50

51 mm

DN 65

63.5 mm

DN 80

76.1 mm

DN 100

101.6 mm

Service kit for product wetted parts, standard

 Service kit, EPDM . . . . . . . . . .

9611926579 9611926580 9611926581 9611926582 9611926583 9611926584

 Service kit, HNBR . . . . . . . . . .

9611926585 9611926586 9611926587 9611926588 9611926589 9611926590

 Service kit, FPM . . . . . . . . . . . .

9611926591 9611926592 9611926593 9611926594 9611926595 9611926596

Parts marked with  are included in the service kits (product wetted parts)

Recommended spare parts: Service kits.

TD 900-383/2

24

25

How to contact Alfa Laval

Contact details for all countries are continually updated on our website.

Please visit www.alfalaval.com to access the information directly.

© Alfa Laval Corporate AB

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.