Alfa Laval UltraPure Series Instruction Manual Download Page 4

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1 CE Declaration of Conformity

The designating company

Alfa Laval

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00

Phone No.

hereby declare that

Radial Diaphragm Valve UltraPure

Diaphragm Valves

November 2011

Denomination

Type

Year

is in conformity with the following directives:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A.

Note: Tank outlet valve is not prepared for build into pressure vessels according to PED/ASME, but only into “open” vessels.

Manager, Product Centres, Compact

Heat Exchangers & Fluid Handling

Bjarne Søndergaard

Title

Name

Alfa Laval Kolding

Company

Signature

Designation

Summary of Contents for UltraPure Series

Page 1: ...2508 0051 ESE02132 EN2 2013 09 Original manual Instruction Manual Radial Diaphragm Valve UltraPure ...

Page 2: ......

Page 3: ...12 4 1 Operation 12 4 2 Troubleshooting 13 4 3 Recommended cleaning 15 5 Maintenance 18 5 1 General maintenance 18 5 2 Dismantling the valve 20 5 3 Diaphragm replacement 21 5 4 Assembly of valve 23 5 5 Disassembly of actuator 24 5 6 Assembly of actuator 27 6 Technical data 28 6 1 Technical data 28 7 Parts list and service kits 30 7 1 Radial Diaphragm Valve UltraPure shut off actuator 30 7 2 Radial...

Page 4: ...pe Year is in conformity with the following directives Machinery Directive 2006 42 EC Pressure Equipment Directive 97 23 EC category 1 and subjected to assessment procedure Module A Note Tank outlet valve is not prepared for build into pressure vessels according to PED ASME but only into open vessels Manager Product Centres Compact Heat Exchangers Fluid Handling Bjarne Søndergaard Title Name Alfa ...

Page 5: ...ormation 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 5 ...

Page 6: ...lve or pipelines when processing hot liquids or when sterilising Never touch the 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 Always release compressed air after use Never service the valve when it is hot Nev...

Page 7: ...eps 2 and 3 2 Delivery note 3 Instruction Manual 4 Q doc Manual Step 2 Shut off valve and tank outlet valve 1 Complete actuator 2 Diaphragm 3 Clamp wingnut or hexnut 4 Valve body 1 2 4 3 2508 0052 Step 3 Manual shut off valve and tank outlet valve 1 Manual actuator 2 Diaphragm 3 Clamp wingnut or hexnut 4 Lower valve body 1 2 4 3 2508 0053 Step 4 Remove any possible packing materials from the valve...

Page 8: ... technical data thoroughly See chapter 6 Technical data Always release compressed air after use CAUTION Alfa Laval cannot be held responsible for incorrect installation Step 2 Never touch the moving parts if the actuator is supplied with compressed air Moving parts 2508 0055 Moving parts Step 3 Avoid putting stress on the valve Pay special attention to Vibrations Thermal expansion of the pipelines...

Page 9: ... fittings on the port ends Step 4 It is recommended to install the valve so that the flow is against the closing direction to avoid water hammer Outlet 2508 0062_1 Inlet Step 5 It is recommended that the leakage hole in the pneumatic manual actuator is placed so it is visible If there is fluid sleeping from the leakage hole the diaphragm is worn out and must be replaced 2508 0063_1 Leakage hole 9 ...

Page 10: ...r 2508 0057 A B Step 2 Placement of the tank outlet valve The valve housing is usually placed according to the figure below but other locations may exist 2508 0058 øC A e g Weldplate mixer A Min distance between the weld in components in accordance with the PED Diameter of weld flange hole Valve size øC 12 7 mm inch ø50 mm 1 97 inch 25 mm 1 inch ø79 mm 3 11 inch 38 mm 1 inch ø85 mm 3 35 inch A hol...

Page 11: ...ases metal straps Wood and cardboard boxes can be reused 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 shoul...

Page 12: ...horoughly See chapter 6 Technical data Always release compressed air after use CAUTION Alfa Laval cannot be held responsible for incorrect operation Step 2 Never touch the valve or pipelines when processing hot liquids or when sterilising The manually handle will get hot use hand protection if the valve must be operated Burning danger 2508 0061 Step 3 Never touch the moving parts if the actuator i...

Page 13: ...essed air supply is too low 5 Pneumatic hose is damaged 6 Solenoid valve fault or forced in wrong position manually 7 Incorrect flow direction in combination with high fluid pressure 1 Inspect diaphragm and replace it if required 2 Correct mounting Some force must be used to push the actuator into the diaphragm 3 Inspect and replace is required 4 Check compressed air supply pressure 5 Replace pneu...

Page 14: ...2 Media has too high temperature 3 Air air actuator has too high air pressure 4 Manual is over tightened 1 Check materials compability EPDM or silicone 2 Lower temperature or EPDM 3 Reduce air pressure to 4 bar 4 Be careful not to tighten to hard External product leaking Telltale hole 1 Diaphragm broken 1 Replace diaphragm Valve leaking 1 Clamp not properly mounted 2 Too high fluid pressure 1 Moun...

Page 15: ...3 Recommended cleaning Step 1 Always handle lye and acid with great care Caustic danger Always use rubber gloves Always use protective goggles Step 2 Never touch the valve or the pipelines when processing hot liquids or when sterilising Burning danger 2508 0061 Step 3 Clean the plug and the seats correctly Pay special attention to the warnings Lift and lower diaphragm momentarily 2508 0062 15 ...

Page 16: ...lb NaOH 26 4 gal water Cleaning agent 2 2 l 33 NaOH 100 l water 0 6 gal 33 NaOH 26 4 gal water Cleaning agent 2 0 5 by weight HNO3 at 70 oC 158 oF 0 7 l 53 HNO3 100 l water 0 2 gal 53 HNO3 26 4 gal water Cleaning agent 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 cleaning Always rinse Clean water C...

Page 17: ...In Place Study the instructions carefully and pay special attention to the warnings NaOH Caustic Soda HNO3 Nitric acid Step 7 Autoclaving The manually opened actuator can be autoclaved Max temperature 130 C 2508 0063 The pneumatic actuator can not be autoclaved 2508 0064 17 ...

Page 18: ...cal data Always release compressed air after use NOTE All scrap must be stored discharged in accordance with current rules directives Step 2 Never service the valve when it is hot Never service the valve with valve and pipelines under pressure Burning danger 2508 0061 Step 3 Never stick your fingers through the valve ports if the actuator is supplied with compressed air Never touch the moving part...

Page 19: ...or and 5 6 Assembly of actuator Planned maintenance Regular inspection for leakage and smooth operation Keep a record of the valve Use the statistics for planning of inspections Replace after leakage Regular inspection for leakage and smooth operation Keep a record of the actuator Use the statistics for planning of inspections Replace after leakage Lubrication Not necessary Inside actuator use Klu...

Page 20: ...ounter clockwise 2 Loosen and remove clamp 3 Release compressed air only NC 4 Lift away the actuator and diaphragm 5 Release compressed air only NC 6 The manually actuator spindle must be in the closed position to remove the diaphragm which is done by rotating the handle clockwise The diaphragm is pushed away from the actuator housing 7 Remove the diaphragm see section 5 3 Diaphragm replacement Ma...

Page 21: ...rking conditions In general inspection should be performed every 50 hours of sterilisation e g exposure to steam or super heated water The interval may however vary between different installations depending on chemicals and utilities used and temperature during SIP The following guidelines can be used 1 Exposure to water 100 C The diaphragm should be inspected after approx 1000 hours of operation ...

Page 22: ...position Some force may be needed to push the diaphragm over the snap connection The diaphragm is mounted onto the actuator rod which must be in the close position diaphragm is uncompressed Fig B Size 38 1 is a screwed connection NOTE The manually actuator must be locked by using small screwdriver into the ø4 hole in the rod ø4 hole is only in the manually rod and not the pneumatic version The dia...

Page 23: ...or rod see section 5 3 Diaphragm replacement Step 2 To fit the actuator onto the valve body the actuator must be in the open position diaphragm is then compressed when assembling the valve Supply compressed air to the actuator only NC and A A The manually handle is turned counter clockwise Step 3 Mount the clamp and be sure that it is fitted correctly Knock with a plastic hammer on both side of th...

Page 24: ...ctuator this can be done safely as there are no springs inside 2508 0065 Step 2 Pneumatic actuator Always release compressed air before dismantling the actuator The pneumatic actuator can be dismantled by using a special tool The part no is shown on the spare part C A B 2508 0081 A Tool to lock the actuator rod to avoid breaking the spring guides inside the actuator B Tool to loosen actuator cap s...

Page 25: ...spring guides inside the housing The actuator can only therefore be opened by the special tool B It is not necessary to use special tool A and C In the pneumatic actuator type NC size ø25 mm 1 inch and ø38 mm 1 1 2 inch there are spring guides inside the housing This is why it its necessary to use the special tool A B and C 1 Remove pressure plate Be careful not to scratch the rod 2508 0079 Type N...

Page 26: ...closed A A Air air activated 3 With actuator compressed mount A locking tool and tighten properly 4 RELEASE COMPRESSED AIR and remove the hose The A locking tool should still lock the rod 2508 0082 A CAREFULLY Spring under load 5 Unscrew cap with tool B spanner wrench 6 Remove piston unit from housing and handle it carefully as spring is under load A 2508 0085 26 ...

Page 27: ... to loosen A locking tool This must be done in a hydraulic press Compress cap and piston and loosen the tool A locking tool in the compressed state 2508 0087 C 8 With the tool A loosen then slowly release the compression in the hydraulic press Careful as springs are under load 2508 0086 2508 0088 5 6 Assembly of actuator CAREFULLY Spring under load Step 1 Assembly is performed in reverse order as ...

Page 28: ... 5 3 for information about the diaphragms Surface treatment Internally High grade polished Ra 0 5 µm or SFI electro polish Ra 0 4 µm SF4 Externally Ra 0 8 µm Operating data for pneumatic actuator Actuator function SA Pneumatic upward movement spring return NC AA Pneumatic upward and downward movement Man Manually operated Operating data Pneumatic actuator Spring operated SA Control air Dry free fr...

Page 29: ...ap correctly Man Manually activated NC Normally closed A A Air air activated 24 5 20 6 3 18 21 2 21 1 16 7 1 10 17 8 15 19 14 4 2 11 12 13 13 12 11 19 15 12 17 10 1 7 21 1 21 2 6 18 16 5 20 23 3 2 14 4 2508 0089 24 5 20 34 31 35 21 2 21 1 33 29 28 30 25 26 27 23 5 20 34 31 35 21 2 21 1 33 29 28 30 25 26 27 2508 0090 29 ...

Page 30: ... scrap correctly Man Manually activated NC Normally closed A A Air air activated 7 1 Radial Diaphragm Valve UltraPure shut off actuator ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 21 1 13 A A 13 A A 14 6 18 16 16 5 1 1 5 5 1 3 18 21 2 10 23 18 7 6 5 1 16 8 13 20 7 12 NC 16 1 3 14 4 13 17 10 19 17 11 NC 11 NC 2 2 12 NC 15 8 4 2508 0047 30 ...

Page 31: ...insert 6 1 Bushing 7 1 Piston 8 1 Spring NC 5 Spring NC 10 1 Clip 11 1 Seal 12 1 Air silencer NC 13 1 Air fitting 2 Air fitting 14 1 O ring 15 1 O ring 16 2 O ring 17 1 O ring 18 1 X ring 2 X ring 19 1 X ring 20 1 Diaphragm 21 1 1 Clamp with wing nut 21 2 1 Clamp with hex nut 23 1 Valve body Service kits Denomination ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 Recommended spare parts Service kit actuator 9...

Page 32: ... and service kits section Handle scrap correctly Man Manually activated NC Normally closed A A Air air activated 7 2 Radial Diaphragm Valve UltraPure shut off manual ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 34 5 1 35 33 5 23 21 1 21 2 30 5 1 1 5 32 20 28 31 31 25 29 25 27 30 29 28 26 26 27 2508 0048 32 ...

Page 33: ...late 5 1 1 Threaded insert 20 1 Diaphragm 21 1 1 Clamp with wing nut 21 2 1 Clamp with hex nut 23 1 Valve body 25 1 Handle 26 1 O ring 27 1 Housing 28 1 O ring 29 1 Spring pin 30 1 Flange 31 1 Rod with bearing 32 1 O ring 33 1 Bushing 34 1 O ring 35 1 O ring Service kits Denomination ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 Recommended spare parts Diaphragm Silicone incl Q doc 9614 0989 01 9614 0989 03 ...

Page 34: ...crap correctly Man Manually activated NC Normally closed A A Air air activated 7 3 Radial Diaphragm Valve UltraPure tank outlet actuator 14 4 15 14 2 13 21 1 17 3 11 NC 11 NC 5 16 10 17 16 6 8 7 1 13 A A 2 12 NC 18 21 2 8 18 3 4 19 5 1 5 1 1 5 1 7 18 13 A A 20 24 12 NC 13 10 16 16 6 2508 0049 ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 34 ...

Page 35: ...ert 6 1 Bushing 7 1 Piston 8 1 Spring NC 5 Spring NC 10 1 Clip 11 1 Seal 12 1 Air silencer NC 13 1 Air fitting NC 2 Air fitting A A 14 1 O ring 15 1 O ring 16 2 O ring 17 1 O ring 18 1 X ring 2 X ring 19 1 X ring 20 1 Diaphragm 21 1 1 Clamp with wing nut 21 2 1 Clamp with hex nut 24 1 Valve body Service kits Denomination ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 Recommended spare parts Service kit actuat...

Page 36: ...and service kits section Handle scrap correctly Man Manually activated NC Normally closed A A Air air activated 7 4 Radial Diaphragm Valve UltraPure tank outlet manual 26 27 5 1 1 5 21 1 21 2 32 26 25 31 28 30 27 29 28 5 30 35 25 34 31 29 33 24 5 1 20 2508 0050 ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 36 ...

Page 37: ...late 5 1 1 Threaded insert 20 1 Diaphragm 21 1 1 Clamp with wing nut 21 2 1 Clamp with hex nut 24 1 Valve body 25 1 Handle 26 1 O ring 27 1 Housing 28 1 O ring 29 1 Spring pin 30 1 Flange 31 1 Rod with bearing 32 1 O ring 33 1 Bushing 34 1 O ring 35 1 O ring Service kits Denomination ø12 7 mm 1 2 ø25 mm 1 ø38 mm 1 1 2 Recommended spare parts Diaphragm Silicone incl Q doc 9614 0989 01 9614 0989 03 ...

Page 38: ...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 Lava...

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