Alfa Laval Unique TO Instruction Manual
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Alfa Laval Unique TO Instruction Manual

Mixproof tank outlet valve
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Instruction Manual
Unique-TO Mixproof Tank Outlet Valve
ESE00156-EN7
Original manual
TD 449-282_1
2017-03

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Summary of Contents for Alfa Laval Unique TO

  • Page 1 Instruction Manual Unique-TO Mixproof Tank Outlet Valve TD 449-282_1 ESE00156-EN7 2017-03 Original manual...

  • Page 3: Table Of Contents

    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 ............... 2. Safety ....................2.1. Important information ................2.2. Warning signs ..................2.3. Safety precautions ................3.

  • Page 4: Ec Declaration Of Conformity

    1 EC Declaration of Conformity Revision of Declaration of Conformity 2009-12-29 The Designated Company Alfa Laval Kolding A/S Company Name Albuen 31, DK-6000 Kolding, Denmark Address +45 79 32 22 00 Phone No. hereby declare that Valve Designation Unique TO...

  • Page 5: Safety

    2 Safety Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special signs. 2.1 Important information 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.

  • Page 6: Safety Precautions

    Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air (see warning label) Never service the valve with valve and pipelines under pressure Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Transportation:...

  • Page 7: Installation

    3.1 Unpacking/intermediate storage Step 1 Check the delivery for: CAUTION! 1. Complete valve 2. Delivery note Alfa Laval cannot be held responsible for incorrect unpacking. 3. Warning label Step 2 Remove upper support Step 3 Lift out the valve. NOTE! Please note weight of valve as printed on box.
  • Page 8 3 Installation The instruction manual is part of the delivery. Study the instructions carefully. Fit the warning label supplied on the valve after installation so that it is normally visible. Step 5 Inspect the valve for visible transport damages. Inspection! Step 6 Avoid damaging the air connections, the leakage outlet, the valve ports and the CIP connections, if supplied.

  • Page 9: Recycling Information

    - 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 3.3 General installation Step 1 - Always read the technical data thoroughly (see 6 Technical data).
  • Page 10 - Thermal expansion of the tubes (especially at long tube lengths) - Excessive welding - Overloading of the pipelines NOTE! TD 449-241 Please follow Alfa Laval installation guidelines (literature code ESE00040). Step 3 Remember seal rings! Fittings: Ensure that the connections are tight.

  • Page 11: Welding

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. Weld carefully/aim at stressless welding to avoid deformation on sealing areas. Check the valve for smooth operation after welding. Step 6 CIP out CIP in...
  • Page 12 - please see later this section! If there is a risk of foot damage, Alfa Laval recommends to leave a distance of 120 mm (4.7”) below the valve (look at the specific built-in conditions).
  • Page 13 3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. Weld carefully/aim at stressless welding to avoid deformation on sealing areas. Check the valve for smooth operation after welding. Step 4 Warning! Make sure to turn the valve body correctly - conical seat...

  • Page 14: Operation

    - Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing). CAUTION! Alfa Laval cannot be held responsible for incorrect operation. Step 2 Never touch the valve or the pipelines when processing hot liquids Burning danger! or when sterilizing.

  • Page 15: Fault Finding And Repair

    4 Operation Study the maintenance instructions carefully before replacing worn parts. - See 5.1 General maintenance 4.2 Fault finding and repair Problem Cause/result Repair Leakage at the leakage detection - Particles between valve seats and - Remove the particles plug seals (56/74) - Check the plug seals pipe (88) - Worn/product affected plug seal...

  • Page 16: Recommended Cleaning

    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 = Nitric acid. Internal leakage in the valve is externally visible by means of the leakage outlet. 4.3 Recommended cleaning Step 1 Caustic danger!
  • Page 17 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 = Nitric acid. Internal leakage in the valve is externally visible by means of the leakage outlet. Step 5 1.
  • Page 18 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 = Nitric acid. Internal leakage in the valve is externally visible by means of the leakage outlet. Step 10 3.

  • Page 19: Maintenance

    Study the instructions carefully and pay special attention to the warnings! Always use genuine Alfa Laval spare parts, and keep spare rubber seals and guide rings in stock. Store seals in closed bag. The items refer to the parts list and service kits section.
  • Page 20 Study the instructions carefully and pay special attention to the warnings! Always use genuine Alfa Laval spare parts, and keep spare rubber seals and guide rings in stock. Store seals in closed bag. The items refer to the parts list and service kits section.

  • Page 21: Dismantling Of Valve

    Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. 5.2 Dismantling of valve Step 1 Disassemble valve acc. to illustrations (1 to 5).
  • Page 22 Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Step 2 If balanced seat lift is available If air fitting AC1 is present, supply compressed air and follow procedure 2A.
  • Page 23 Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Step 3 Remove coupling system and balanced plug according to illustrations (1 to 4).

  • Page 24: Tank Plug, Replacement Of Radial Seal

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Always use genuine Alfa Laval spare parts. Handle scrap correctly. 5.3 Tank plug, replacement of radial seal Step 1 Cut and remove old seal ring (74) using a knife, screwdriver or similar.

  • Page 25: Balanced Plug, Replacement Of Axial Seal

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Always use genuine Alfa Laval spare parts. Handle scrap correctly. Step 4 Tool marked with item 1. Place upper tool part including piston.
  • Page 26 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Always use genuine Alfa Laval spare parts. Handle scrap correctly. Step 2 Pre-mount seal ring as shown on drawing. A = Flat side of the sealing...

  • Page 27: Assembly Of Valve

    Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Step 6 1. Inspect the seal. 2. Release air at 3 different positions of the circumference.
  • Page 28 Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Step 3 Place coupling system and balanced plug according to illustrations ( 1 to 4 ).
  • Page 29 Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Step 5 - Never stick your fingers through the valve ports if the actuator is supplied with compressed air.

  • Page 30: Dismantling Of Acutator

    Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary. 5.6 Dismantling of acutator Step 1 1. Dismantle the valve in accordance with instructions in section 5.2 Dismantling of valve . Pay special attention to the warnings! 2.
  • Page 31 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. Always use genuine Alfa Laval spare parts. Replace seals if necessary.

  • Page 32: Assembly Of Actuator

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Lubricate the rubber seals before fitting them. 5.7 Assembly of actuator Step 1 Please see drawing when reassembling according to steps 2 to 5 on this page.
  • Page 33 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Always use genuine Alfa Laval spare parts. Replace seals if necessary. Lubricate the rubber seals before fitting them.

  • Page 34: Technical Data

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform the personnel about the technical data. 6.1 Technical data Unique is remote-controlled by means of compressed air. The valve is a normally closed (NC) valve. The valve has two independent plug seals, forming a leakage chamber.
  • Page 35 Weight (kg) Longstroke Size DN/OD DN/OD ISO-DIN 63.5 76.1 101.6 150 63.5 76.1 Weight (kg)* Unique TO 12.5 22.5 22.5 12.5 22.5 22.5 Weight (kg)* Unique TO with external cleaning 23.5 23.5 23.5 23.5 - - - *= without tank flange...

  • Page 36: Parts List And Service Kits

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.1 Actuator **11 **11.1 15.1 = actuator kit 2306-0005 = Not used in actuator 1½”-2”...
  • Page 37 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Upper stem Screw Air fitting Air fitting...

  • Page 38: Plug Setup 6 (Tank Flange)

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.2 Plug setup 6 (tank flange) 2306-0007 = wear parts * = with SpiralClean in leakage chamber...
  • Page 39 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Plug  O-ring, EPDM O-ring, EPDM O-ring, EPDM...

  • Page 40: Plug Setup 12 (Tank Flange)

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.3 Plug setup 12 (tank flange) 2306-0008 2306-0009 = wear parts...
  • Page 41 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Plug O-ring, EPDM  O-ring, EPDM O-ring, EPDM...

  • Page 42: Plug Setup 6 (Stub Flange)

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.4 Plug setup 6 (stub flange) 2306-0007 = wear parts * = with SpiralClean in leakage chamber...
  • Page 43 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Plug  O-ring, EPDM O-ring, EPDM O-ring, EPDM...

  • Page 44: Plug Setup 12 (Stub Flange)

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.5 Plug setup 12 (stub flange) 2306-0008 2306-0009 = wear parts...
  • Page 45 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Plug  O-ring, EPDM O-ring, EPDM O-ring, EPDM...

  • Page 46: Valve Bodies

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.6 Valve bodies 2306-0011...
  • Page 47 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Intermediate piece Valve body, upper Clamp with screws...

  • Page 48: Installation Kit B

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.7 Installation kit B TD 449-306...
  • Page 49 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Hose PTFE with stainless steel weave Welding socket...

  • Page 50: Installation Kit C

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.8 Installation kit C TD 449-307...
  • Page 51 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Welding liner...

  • Page 52: Installation Kit G

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.9 Installation kit G TD 449-308...
  • Page 53 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Welding male part, AISI 316 3/8" 10 mm Female PVDF...

  • Page 54: Installation Kit H And H2

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.10 Installation kit H and H2 TD 449-309...
  • Page 55 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination DIN union DN10 12 mm CIP pipe long...

  • Page 56: Axial Installation Tool

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.11 Axial installation tool TD 449-038_1...
  • Page 57 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Lower Part Piston Upper Part O-ring, NBR...

  • Page 58: Radial Installation Tool

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.12 Radial installation tool TD 449-354...
  • Page 59 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Piston Lower Part Upper Part Bushing Guide...

  • Page 60: Mounting Tool For Lip Seal

    Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. 7.13 Mounting tool for lip seal TD 449-310...
  • Page 61 Parts list and service kits Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts. Parts list Pos. Denomination Mounting tool for lip seal...
  • Page 62 © 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.

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