Alfa Laval UltraPure Series Instruction Manual
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Alfa Laval UltraPure Series Instruction Manual

Alfa Laval UltraPure Series Instruction Manual

Radial diaphragm valve
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Instruction Manual
Radial Diaphragm Valve UltraPure
ESE02132-EN2
Original manual
2013-09
2508-0051

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Summary of Contents for Alfa Laval UltraPure Series

  • Page 1 Instruction Manual Radial Diaphragm Valve UltraPure 2508-0051 ESE02132-EN2 2013-09 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. CE Declaration of Conformity ............... 2. Safety ....................2.1. Important information ................2.2. Warning signs ..................2.3. Safety precautions ................3.

  • Page 4: Ce Declaration Of Conformity

    - 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 Bjarne Søndergaard Heat Exchangers & Fluid Handling Title Name Alfa Laval Kolding Company Signature Designation...

  • Page 5: Safety

    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 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

    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.

  • Page 7: Installation

    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.

  • Page 8: General Installation

    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 Moving Never touch the moving parts if the actuator is supplied with parts! compressed air.
  • Page 9 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.

  • Page 10: Welding

    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. Step 2 Placement of the tank outlet valve...

  • Page 11: Recycling Information

    - At the end of use, the equipment should be recycled according to relevant, local regulations. Apart from 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 the local Alfa Laval sales company.

  • Page 12: Operation

    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 operation. Step 2 Never touch the valve or pipelines when processing hot liquids or when sterilising.

  • Page 13: Troubleshooting

    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 Problem Possible cause Repair Manual valve does not open when 1. Diaphragm has stuck. 1. Inspect diaphragm and replace it if 2.
  • Page 14 4 Operation Pay attention to possible faults. Study the instructions carefully. The items refer to the Parts list and service kits section. Repair Problem Possible cause Water hammer. The flow direction is the same as the The flow direction should be against the closing direction.

  • Page 15: Recommended Cleaning

    4 Operation The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic Soda. = Nitric acid. 4.3 Recommended cleaning Step 1 Caustic danger! Always handle lye and acid with great care.
  • Page 16 4 Operation The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic Soda. = Nitric acid. Step 4 Examples of cleaning agents: Use clean water, free from chlorides.
  • Page 17 4 Operation The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic Soda. = Nitric acid. Step 7 Autoclaving The manually opened actuator can be autoclaved. Max.

  • Page 18: Maintenance

    5 Maintenance Maintain the valve regularly. Study the instructions carefully and pay special attention to the warnings! Always keep spare rubber seals in stock. Check the valve for smooth operation after service. 5.1 General maintenance Step 1 NOTE All scrap must be stored/discharged in accordance with current rules/directives.
  • Page 19 5 Maintenance Maintain the valve regularly. Study the instructions carefully and pay special attention to the warnings! Always keep spare rubber seals in stock. Check the valve for smooth operation after service. Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal working conditions in one shift.

  • Page 20: Dismantling The Valve

    5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 5.2 Dismantling the valve Step 1 The actuator must be in the “open position” when dismantling the clamp. Danger! Always make sure that there is no product pressure in the pipeline before opening the valve.

  • Page 21: Diaphragm Replacement

    5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 5.3 Diaphragm replacement The diaphragm seals against the valve body seat while the valve is closed. The diaphragm also operates as a static seal. There are two sealing faces between the valve housing and the actuator.
  • Page 22 5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Diaphragm marking Fig. A Size 12.7 / ½ inch and 25 / 1 inch is “a snap connection”. The diaphragm must be all the way on, or it will be over-stretched and damaged in the closed position.

  • Page 23: Assembly Of Valve

    5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 5.4 Assembly of valve Step 1 Start by fitting the diaphragm onto the actuator 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.

  • Page 24: Disassembly Of Actuator

    5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 5.5 Disassembly of actuator Step 1 Manual actuator The manually operated actuator can not be dismantled.
  • Page 25 5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Type NC: In the pneumatic actuator type NC ø12.7 mm / 1/2 inch there are no “spring guides” inside the housing. The actuator can only therefore be opened by the special tool “B”.
  • Page 26 5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 3) With actuator compressed mount “A” (locking tool) and tighten properly.

  • Page 27: Assembly Of Actuator

    5 Maintenance Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Hydraulic press CAREFULLY - Spring under load 7) Fit “C” (distance piece) so it is possible to loosen “A” (locking tool).

  • Page 28: Technical Data

    Technical data Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 6.1 Technical data Design temperature Max. 135 °C / (275 °F) (at 1 hour) Sterilisation In Place (SIP) Autoclave clearing Pneumatic actuator can not be autoclaved.
  • Page 29 Technical data Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 21.2/21.1 21.1/21.2 2508-0089 21.2/21.1 21.2/21.1 2508-0090...

  • Page 30: Parts List And Service Kits

    7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle 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”...
  • Page 31 7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Parts list Pos. Denomination Actuator, complete (NC) Actuator, complete (A/A) Actuator housing...

  • Page 32: Radial Diaphragm Valve Ultrapure - Shut Off - Manual

    7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list 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”...
  • Page 33 7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Parts list Pos. Denomination Manual handle, complete Pressure plate Threaded insert...

  • Page 34: Radial Diaphragm Valve Ultrapure - Tank Outlet - Actuator

    7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. 7.3 Radial Diaphragm Valve UltraPure - tank outlet - actuator 21.1 21.2 5 (1")
  • Page 35 7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Parts list Pos. Denomination Actuator, complete (NC) Actuator, complete (A/A) Actuator housing...

  • Page 36: Radial Diaphragm Valve Ultrapure - Tank Outlet - Manual

    7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list 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 21.1 21.2 5 (1")
  • Page 37 7 Parts list and service kits Study the instructions carefully. The items refer to the Parts list and service kits section. Handle scrap correctly. Man = Manually activated NC = Normally closed. A/A = Air/air activated. Parts list Pos. Denomination Manual handle, complete Pressure plate Threaded insert...
  • Page 38 © 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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