Alfalaval UltraPure Series Bedienungsanleitung

2508-0051

ESE02132-EN2 2013-09

Original manual

Instruction Manual

Radial Diaphragm Valve UltraPure

Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

1. CE 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 ............................................................................................ 10

3.4. Recycling information ............................................................................. 11

4. Operation ............................................................................................... 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 Diaphragm Valve UltraPure - shut off - manual ........................................ 32

7.3. Radial Diaphragm Valve UltraPure - tank outlet - actuator ................................... 34

7.4. Radial Diaphragm Valve UltraPure - tank outlet - manual ..................................... 36

1 CE Declaration of Conformity

The designating company

Alfa Laval

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+4579322200

Phone No.

hereby declare that

Radial Diaphragm Valve UltraPure Diaphragm Valves November 2011

Denomination Type Year

is in conformity with the following directives:

-Mac

hinery 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

2 Safety

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

Warnings are emphasised by means of special signs.

2.1 Important information

Alwaysreadthemanualbeforeusingthevalve!

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

All warnings in the manual are summarised on this page.

Pay special attention to the 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)

Always release compressed air after use.

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

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

Never dismantle the valve with the valve and pipelines under pressure.

Never dismantlethevalvewhenitishot.

Operation:

Never dismantle the valve with the valve and pipelines under pressure.

Never dismantlethevalvewhenitishot.

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

Always release compressed air after use.

Never touch the valve 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.

Never service the valve with the valve and pipelines under pressure.

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.

Transportation:

Always secure that compressed air is released.

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

Always drain liquid out of valves before transportation.

Always use pre-designed lifting points if defined.

Always secure 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).

3.1 Unpacking/delivery

Step 1

CAUTION

Alfa Laval cannot be held responsible for incorrect unpacking.

Check the delivery for:

1. Complete valve, shut off valve, tank outlet, manual shut off or

manual tank outlet valve (see steps 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

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

2508-0053

Step 4

Remove any possible packing materials from the valve/valve parts

Step 5

Inspect the valve and valve parts for visible transport damages.

Avoid damaging the valve and valve parts.

Check that the Q-doc. serial number and the “Q-doc manual

number” are identical.

2508-0054

Q-doc serial number

3 Installation

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

The valve has welding ends and a clamp fitting on the bottom as standard but can also be supplied with clamp fittings on

the port ends.

3.2 General installation

Step 1

Always read the 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

- Excessive welding

- Overloading of the pipelines

2508-0056

Risk of damage!

3 Installation

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

The valve has welding ends and a clamp fitting on the bottom as standard but can also be supplied with clamp 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

3 Installation

Study the instructions carefully.

The valve is supplied as separate parts to facilitate welding. The items refer to the Parts list and service kits section.

Check the valve for smooth operation after welding. Man = Manually open and close, NC = Normally closed.

3.3 Welding

Step 1

Always weld the valve so that the actuator with the internal parts

can be removed.

Valve size

DN/OD

Amm(inch)

Air actuator

Bmm(inch)

Manual actuator

12.7 mm (½ inch) 132 mm (5.2 inch) 92 mm (3.6 inch)

25 mm (1 inch) 168 mm (6.6 inch) 98 mm (3.9 inch)

38 mm (1½ inch) 182 mm (7.1 inch) 112 mm (4.4 inch)

NOTE! If there is a risk of foot damage, Alfa Laval recommends to

leave a distance of 120 mm (4.7”) below the actuator.

2508-0057

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

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 / ½ inch ø50 mm / 1.97 inch

25 mm / 1 inch ø79 mm / 3.11 inch

38 mm / 1½ inch ø85 mm / 3.35 inch

A hole (see table) for the valve is cut in the tank plate.

Grind the edge so there is no gap between valve and tank plate.

Only use pulsed arc welding (low heat input) to avoid deforming the valve body.

Tack weld always on the opposite side (8 segments with filler metal).

Weld root if possible without filler metal.

Welding of the final run must be done in 8 segments to avoid cracking.

The inside and outside of the weld is ground and polished to the required finish.

TD 449-244

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