Alfa Laval Unique SSV PN10 Instruction Manual Download Page 16 | Manualshive

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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.
Check the valve for smooth operation after service.

5.1

General maintenance

Step 1

Always read the technical data thoroughly. See chapter 6 Technical data.

Always release compressed air after use.

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

Step 2

Never service the valve when it is hot.

Never service the valve with valve and pipelines under pressure.

Atmospheric
pressure
required!

Danger of burns!

Step 3

Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.

Air

Danger of cuts!

Air

Step 4

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

Air

Moving parts!

Air

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Summary of Contents for Unique SSV PN10

Page 1: ...ESE00202 EN9 2015 04 Original manual Instruction Manual Unique Single Seat Valve Standard and Reverse Acting ...

Page 2: ......

Page 3: ...enance 16 5 1 General maintenance 16 5 2 Dismantling the valve 18 5 3 Plug seal replacement 19 5 4 Assembly of valve 19 5 5 Actuator bushing replacement 20 5 6 Dismantling of optional maintainable actuator 25 5 7 Mounting of optional maintainable actuator 25 5 8 Additional equipment 25 6 Technical data 26 6 1 Technical data 26 7 Parts list and service kits 27 7 1 Drawing 27 7 2 Unique Single Seat ...

Page 4: ... declare that Valve Designation Unique SSV PN10 Type From serial number 5099880 to 29999999999 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC Regulation EC No 1935 2004 The person authorised to compile the technical file is the signer of this document QHSE Manager Quality Health and safety Environment Annie Dahl Title Name Kolding 2013 12 03 Place Date...

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: ...e Alfa Laval recommends max 3 bar Plastic adapter pos 5 is always used on the new design ø157 5 mm TD 461 990 5 Actuators marked with year 2006 2011 old actuator design WARNING Max 3 bar support air on spring side When using support air on spring side in all the Unique SSV actuators the pressure must NOT exceed 3 bar When using Unique SSV actuators with ø156mm with support air always use the steel...

Page 7: ...ipelines when processing hot liquids or when sterilising 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 Always release compressed air after use Never service the valve when it is hot Never service t...

Page 8: ...rect unpacking Check the delivery for 1 Complete valve shut off valve RA or change over valve RA see steps 2a 2b 2c and 2d 2 Delivery note Step 2 2a Shut off valve 1 Complete actuator 2 Bonnet 20 3 Clamp 19 4 Valve plug 23 5 Valve body 22 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 TD 461 020_1 ...

Page 9: ...assembled before delivery if it is supplied with fittings 2d Change over valve Reverse Acting 1 Complete actuator 2 Bonnet 20 3 4 x clamps 19 4 Upper valve plug 34 5 Lower valve plug 35 6 3 x upper valve bodies 26 7 2 x valve seats 28 8 Lower bonnet 33 UP TD 461 022_1 Step 3 Remove possible packing materials from the valve valve parts Inspect the valve valve parts for visible transport damage Avoi...

Page 10: ...fa Laval cannot be held responsible for incorrect installation Step 2 Never touch moving parts if the actuator is supplied with compressed air Air Moving parts Air Step 3 To avoid water hammer it is recommended to install the valve so that the flow is against the closing direction Shock in the actuator must never occur Avoid water hammering Inlet Inlet Step 4 Avoid stressing the valve Pay special ...

Page 11: ...laced Do not weld more than one valve body into the system Valve size A mm B mm DN25 25 mm 630 DN40 38 mm 700 DN50 51 mm 750 DN65 63 5 mm 740 DN80 76 mm 800 DN100 101 6 mm 790 Depending on body combination and piping solution B incl top unit A Step 2 Assemble the valve in accordance with the steps on page 19 Pay special attention to the warnings Step 3 Pre use check 1 Supply compressed air to the ...

Page 12: ...l 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 e...

Page 13: ...pressed air after use 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 Danger of burns Step 3 Never touch moving parts if the actuator is supplied with compressed air Air Moving parts Air Step 4 Lubrication of valves 1 Ensure smooth movement between lip seal 25 and plug stem 23 27 2 L...

Page 14: ...different rubber grade Internal product leakage Worn or product affected plug seal Replace the seal Replace with a seal of a different rubber grade Product deposits on the seat and or plug Frequent cleaning Product pressure exceeds actuator specification Replace with a high pressure actuator Use auxiliary air on the spring side do not exceed 3 bar See 2 3 Safety precautions Reduce product pressure...

Page 15: ...l attention to the warnings Lift and lower valve plug momentarily Shut off valve Change over valve Step 4 Examples of cleaning agents Use clean water free from chlorides 1 1 by weight NaOH at 70o C 2 0 5 by weight HNO3 at 70o C 1 kg NaOH 100 l water Cleaning agent 0 7 l 53 HNO3 100 l water Cleaning agent 2 2 l 33 NaOH 100 l water Cleaning agent Step 5 1 Avoid excessive concentration of the cleanin...

Page 16: ...ta Always release compressed air after use NOTE All scrap must be stored discharged in accordance with current regulations directives Step 2 Never service the valve when it is hot Never service the valve with valve and pipelines under pressure Atmospheric pressure required Danger of burns Step 3 Never stick your fingers through the valve ports if the actuator is supplied with compressed air Air Da...

Page 17: ...leakage leakage normally starts slowly Replace at the end of the day Replace when possible Planned maintenance Regular inspection for leakage and smooth operation Keep a record of the valve Use the statistics for inspection planning Replace after leakage Regular inspection for leakage and smooth operation Keep a record of the actuator Use the statistics for inspection planning Replace after leakag...

Page 18: ...o the actuator only NO 6 Unscrew and remove valve plug 7 Release compressed air only NO 8 Remove seat and O rings 9 Loosen and remove upper clamp 10 Remove upper valve body 11 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 pa...

Page 19: ...p 14 Remove upper valve body 15 Unscrew and remove upper valve plug 16 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 page 19 UP UP TD 462 003_2 UP 5 3 Plug seal replacement 1 Remove old seal ring using a knife screwdriver or...

Page 20: ...ick o ring inside and the thin o ring outside the bushing Always lubricate the spindle and o rings thoroughly with Molykote LongTerm 2 Plus before mounting the new bushings 2200 0000 Step 2 Introduction Standard socket wrench Use a 27 mm socket wrench to mount the bushings as the space in the yoke is limited A socket wrench 24x27 length 185 mm is a standard tool which can be purchased from all too...

Page 21: ...entre by the internal spring see drawing below In these cases the alignment spindle shown below together with the socket wrench is a great help and ensures a reliable mounting of the bushing The spindle can either be purchased from Alfa Laval together with the socket wrench 9614 1984 01 or it can be manufactured locally using the below dimensions Spindle forced off centre by spring inside actuator...

Page 22: ...ol See spare parts Step 1 The actuator must be carefully fixed in a vice if it is dismounted from the valve Be careful not to press the yoke flange oval when fixing the actuator in the vice Only fix carefully on the yoke leg as shown below 2200 0005 2200 0006 Step 2 Remove adapter screw After spindle alignment the adapter screw has to be remounted 2200 0007 22 ...

Page 23: ...r air activated Service tool See spare parts Step 3 1 Lubricate thoroughly both the actuator spindle and o rings 2 Grease with Molykote LongTerm 2 plus 3 Fit the bushing on the spindle 2200 0008 Step 4 Fit the aligning spindle to the actuator spindle and then mount the socket wrench 2200 0009 2200 0010 Aligning spindle Socket wrench 23 ...

Page 24: ...ed Service tool See spare parts Step 5 Now pull the aligning spindle to centre the actuator spindle In this position rotate the bushing 180 backwards and then begin to fasten the bushing Make sure that the thread catches evenly The bushing must only be tightened with a torque of 10 Nm 7 lbf ft which can be done by turning hard by hand 2200 0011 24 ...

Page 25: ... ring and spring assembly 7 Remove O rings and support disc Rotate cylinder with service tool Note The A A actuator has no spring assembly TD 461 033 5 7 Mounting of optional maintainable actuator Reverse order of 5 6 Dismantling of optional maintainable actuator Lubricate O rings 3 7 11 with Molykote Longterm 2 plus before fitting 5 8 Additional equipment 1 Rotate cylinder 2 Remove lock wire and ...

Page 26: ...d EPDM seal Air pressure actuator 500 to 700 kPa 5 to 7 bar Materials valve actuator Product wetted steel parts 1 4404 316L internal Ra 0 8 µm Other steel parts 1 4301 304 Plug seal EPDM PTFE TR2 Other product wetted seals EPDM standard Optional product wetted seals HNBR and FPM Other seals NBR Weight kg Inch tubes DN OD DIN tubes DN Nominal size 25 38 51 63 5 76 1 101 6 25 40 50 65 80 100 Stop va...

Page 27: ...7 Parts list and service kits The drawing shows Unique Single Seat Valve The items refer to the parts list in the following sections 7 1 Drawing Shut off valve Change over valve 27 ...

Page 28: ...e kits The drawing shows Unique Single Seat Valve Shut off The items refer to the parts lists in the following sections 7 2 Unique Single Seat Valve Shut off Valve Standard shut off valve 25 101 6 mm DN25 100 TD 461 075_1 28 ...

Page 29: ...DN 65 63 5 mm DN 80 76 1 mm DN 100 101 6 mm Service kit for actuator Service kit actuator 9611926500 9611926500 9611926500 9611926500 9611926500 9611926500 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 96119...

Page 30: ...ue Single Seat Valve Change over The items refer to the parts lists in the following sections 7 3 Unique Single Seat Valve Change over Valve Standard change over valve 25 101 6 mm DN25 100 TD 461 969 25 mm DN25 38 51 mm DN40 50 63 5 101 6 mm DN65 100 30 ...

Page 31: ...Plug seal 28 1 Seat Service kits Service kit for actuator Service kit actuator 9611926500 9611926500 9611926500 9611926500 9611926500 9611926500 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 96119...

Page 32: ... 32 ...

Page 33: ...t and service kits The drawing shows Unique Single Seat Valve Change over The items refer to the parts lists in the following sections 7 4 Drawing Shut off valve Reverse Acting Change over valve Reverse Acting 33 ...

Page 34: ... kits The drawing shows Unique Single Seat Valve Reverse Acting Shut off The items refer to the parts lists in the following sections 7 5 Unique Single Seat Valve Reverse Acting Shut off Valve Reverse Acting shut off valve 34 ...

Page 35: ...bonnet Service kits 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 actuator Service kit 9611926500 9611926500 9611926500 9611926500 9611926500 9611926500 Service kit for product wetted parts standard Service kit EPDM 9611926525 9611926526 9611926527 9611926528 9611926529 9611926530 Service kit HNBR 9611926531 9611926532 9611926533 96119...

Page 36: ...drawing shows Unique Single Seat Valve Reverse Acting Change over The items refer to the parts lists in the following sections 7 6 Unique Single Seat Valve Reverse Acting Change over Valve Reverse Acting change over valve TD 462 054 36 ...

Page 37: ... Plug 35 1 1 Plug 35 2 1 Plug seal Service kits 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 actuator Service kit 9611926500 9611926500 9611926500 9611926500 9611926500 9611926500 Service kit for product wetted parts standard Service kit EPDM 9611926597 9611926598 9611926599 9611926600 9611926601 9611926602 Service kit HNBR 9611926603...

Page 38: ...d service kits The drawing shows Unique Single Seat Valve Reverse Acting Change over The items refer to the parts lists in the following sections 7 7 Maintainable actuator Maintainable actuator 25 101 6 mm DN25 100 38 ...

Page 39: ...2 Air fitting only 2 for A A 13 1 Yoke 14 1 Spring assembly 15 1 Bottom 16 1 2 Support disc only 2 for A A 17 3 Washer 18 3 Nut Service kits 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 actuator Service kit NO NC 9611926497 9611926497 9611926498 9611926498 9611926499 9611926499 Service kit A A 9611926519 9611926519 9611926520 96119265...

Page 40: ...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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