Alfa Laval 6357 Instruction Manual
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Alfa Laval 6357 Instruction Manual

Alfa Laval 6357 Instruction Manual

Safety valve
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Alfa Laval Safety Valve
Safety valves
2001-0000
Instruction Manual
Lit. Code
200007932-2-EN-GB
BRITISH ENGLISH

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  • Page 1 Alfa Laval Safety Valve Safety valves 2001-0000 Instruction Manual Lit. Code 200007932-2-EN-GB BRITISH ENGLISH...
  • Page 2 © Alfa Laval AB 2024-12 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). No part of this document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval’s prior express written permission. Information and services provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose.

  • Page 3: Table Of Contents

    Contents 1 Declarations of Conformity .................5 EU Declaration of Conformity..................5 UK Declaration of Conformity..................6 2 Safety ..........................7 Safety Signs......................8 Safety Precautions....................10 Warning Signs in Text....................15 Requirements of Personnel..................16 Recycling Information....................17 3 Introduction .........................19 General Description....................19 4 Installation ........................
  • Page 4 Ordering Spare Parts....................47 Alfa Laval Service....................47 Warranty - Definition....................48 9 Parts Lists and Exploded Views ..............49 Standard........................49 Standard with Inductive Sensor................50 Pneumatic Lifting with Inductive Sensor..............51 Manual Lifting......................52...

  • Page 5: Declarations Of Conformity

    1 Declarations of Conformity 1.1 EU Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Safety Valve Designation 6357 Type...

  • Page 6: Declaration Of Conformity

    1 Declarations of Conformity 1.2 UK Declaration of Conformity The designated company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Safety Valve Designation 6357 Type...

  • Page 7: Safety

    Instruction Manual without prior notice or any obligation. The English version of the Instruction Manual is the original manual. Alfa Laval cannot be held responsible for incorrect translations. In case of doubt, the English version applies.

  • Page 8: Safety Signs

    2 Safety 2.1 Safety Signs Mandatory Action Signs General mandatory action sign. Refer to instruction manual. Use eye protection - safety glasses. Use protective hand wear - safety gloves. Wear protective equipment - safety helmet. Use ear protection in noisy environments - noise protector. Wear protective equipment - safety shoes.
  • Page 9 Safety 2 Crushing of hands. Danger of injury Do not attempt to disassemble the actuator due to spring under load danger! DO NOT DISASSEMBLE 200007932-2-EN-GB...

  • Page 10: Safety Precautions

    Always ensure that compressed air is released. Always use designated lifting points if defined. Ensure that the lifting equipment is suitable for the supplied Alfa Laval product. Always ensure that the unit is securely fixed during transporta- tion. Always ensure the lifting point to be in line with center of gravity.
  • Page 11 Safety 2 Installation If the local safety regulations prescribe that the installation has to be inspected and approved by responsible authorities before the valve is put into service, consult with such authorities before in- stalling the equipment and have the projected installation ap- proved by them.

  • Page 12: Maintenance

    2 Safety Maintenance In order to optimise the operation of the supplied Alfa Laval prod- uct and to minimize the down time due repair activities, the main- tenance includes: • Inspection and maintenance of the supplied Alfa Laval prod- uct: strictly follow the technical documentation •...
  • Page 13 Safety 2 Hazards Burn Hazard • Lubrication oil, machine parts and various machine surfaces can be hot and cause burns. Wear protective gloves Corrosive Hazard • Always handle cleaning liquids, lye and acid with great care and in accordance with separate instructions for those fluids •...

  • Page 14: Safety Check

    Safety check A visual inspection of any protective device (shield, guard, cover or other) on the supplied Alfa Laval product shall be carried out at least every 12 months. If the protective device is lost or damaged, especially when this leads to deterioration of safety performance, it shall be replaced.

  • Page 15: Warning Signs In Text

    Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate damage to the supplied Alfa Laval product. NOTE Indicates important information to simplify or clarify procedures. 200007932-2-EN-GB...

  • Page 16: Requirements Of Personnel

    Trainees can perform tasks under the supervision of an experienced employee. People in general The public shall not have access to the supplied Alfa Laval product. In some cases, specially skilled personnel may need to be hired (i.e. electricians, welders). In some cases the personnel has to be certified according to local regulations with experience of similar types of work.

  • Page 17: Recycling Information

    Metal straps should be sent for material recycling Maintenance During maintenance, oil (if used) and wear parts in the supplied Alfa Laval product should be replaced. • Oil and all non-metal wear parts must be disposed of in accordance with local regulations •...
  • Page 18 This page is intentionally left blank.

  • Page 19: Introduction

    3.1 General Description The Alfa Laval Safety Valve is a spring loaded safety valve used to prevent overpressures in tanks and vessels in the dairy, food and beverage, and biopharm industries to reliably avoid damages to human beings and equipment.
  • Page 20 This page is intentionally left blank.

  • Page 21: Installation

    4 Installation 4.1 Unpacking/delivery CAUTION Alfa Laval cannot be held responsible for incorrect unpacking. Check the delivery: 1. Complete valve. 2. Delivery note. a) Clean the valve of possible packing materials. b) Inspect the valve for visible transport damage. c) Avoid damaging air and pipe connections.

  • Page 22: General Installation

    Always read the technical data thoroughly. See Technical Data on page 39 CAUTION Alfa Laval cannot be held responsible for incorrect installation. WARNING Always release compressed air after use. Avoid stressing the valve as this can cause deformation of the sealing area and malfunction of the valve (leakage or faulty indication).

  • Page 23: Indication And Control Equipment (Optional Extras)

    Installation 4 4.3 Indication and control equipment (optional extras) CAUTION The indication and control equipment must be electrically installed by authorised personnel only. Inductive proximity switches It is recommended to adjust the sensor (A) so it will give feedback when the valve is closed. Lock the sensor with the nut (B).
  • Page 24 This page is intentionally left blank.

  • Page 25: Operation

    NOTE Always read the technical data thoroughly. (See Technical Data on page 39) CAUTION Alfa Laval cannot be held responsible for incorrect operation. WARNING Never touch the valve or the pipelines when processing hot liquids or when sterilising. DANGER Burn hazard!

  • Page 26: Fault-Finding

    5 Operation 5.2 Fault-finding NOTE Study the maintenance instructions carefully before replacing worn parts - see General maintenance on page 29. Pay attention to possible break-down. Study the instructions carefully. Problem Cause/result Repair Internal leakage Worn O-rings Replace the O-rings Worn flange O-rings External leakage Replace all seals...

  • Page 27: Recommended Cleaning

    Operation 5 5.3 Recommended Cleaning NOTE The supplied product is designed for cleaning in place (CIP). NaOH = Caustic soda. = Nitric acid. The cleaning agents must be stored/disposed of in accordance with current regulations/directives. CAUTION Never touch the supplied product or the pipelines when sterilizing. Always handle lye and acid with great care.

  • Page 28: Optimum Cleaning During The Cleaning Cycle

    5 Operation 5.3.1 Optimum cleaning during the cleaning cycle To secure optimum cleaning of the cavity between valve during the cleaning cycle, please follow the recommendations below. Standard version: It is not possible to clean the valve inside the valve cavity. Pneumatic version: Supply air to the air connection when cleaning the valve.

  • Page 29: Maintenance

    6 Maintenance 6.1 General maintenance NOTE Always read the technical data thoroughly. See Technical Data on page 39 All scrap must be stored/discharged in accordance with current rules/directives. WARNING Always release compressed air after use. Never service the valve when it is hot. Never stick your fingers through the valve ports if the actuator is supplied with compressed air.

  • Page 30: Lubrication Recommendation

    6 Maintenance DANGER Cutting hazard! Atmospheric pressure required! The valve/actuator and the pipelines must never be pressurised when servicing the valve/actuator. Never stick your fingers through the valve ports if the actuator is supplied with compressed air. 2001-0005 The maintenance intervals depend on the operating conditions. •...
  • Page 31 Maintenance 6 Product wetted seals Preventive maintenance Replace after 12 months Maintenance after leakage Replace at the end of the day (leakage normally starts slowly) • Regular inspection for leakage and smooth operation • Keep a record of the valve Planned maintenance •...

  • Page 32: Disassembly And Assembly

    6 Maintenance 6.2 Disassembly and assembly NOTE Study the instructions carefully. The items refer to the Parts Lists and Exploded Views on page 49. 6.2.1 DN25 - Replacement of product wetted seals a) Remove electrical lines, sensor mounting and control air! b) Unscrew the electrical lines (P) from sensor (32).
  • Page 33 Maintenance 6 a) Unscrew the slotted nut (30) from the housing (1) with a hook wrench (M4). b) Dismantle the complete valve insert from the housing (1). 2001-0008 Unscrew the housing (1) from the screw in socket (2) and remove the O-ring (21). 2001-0009 200007932-2-EN-GB...
  • Page 34 6 Maintenance a) Unscrew the piston plate (4) from the piston (5). b) Remove O-ring (20). 2001-0010 a) Remove the piston (5) and piston rod (9) axially out of the housing (11). b) Remove O-ring (22). 2001-0011 Puncture the shaft sealing (23) at the centre with a pointed tool (M3) and remove it from the groove.

  • Page 35: Dn40-100 - Replacement Of Product Wetted Seals

    Maintenance 6 6.2.2 DN40–100 - Replacement of product wetted seals a) Remove electrical lines, sensor mounting and control air. b) Unscrew the electrical liner (P) from sensor (32). c) Unscrew the screw (35) and remove bracket (34). 2001-0013 Without removing the sealing (28) and changing the set pressure the following seals are replaced.
  • Page 36 6 Maintenance a) Unscrew the clamp coupling (31). b) Dismantle the complete valve insert from the housing (1). 2001-0015 Unscrew housing (1) from the screw-in socket (2) and remove the O-rings (21). 2001-0016 200007932-2-EN-GB...
  • Page 37 Maintenance 6 a) Unscrew the piston plate (4) from the piston (5). b) Remove O-ring (20). a) Unscrew the piston plate (5) from the piston rod (9). b) Remove the piston (5) and piston rod (9) axially out of the housing (11). c) Remove O-ring (22).

  • Page 38: Disassembly - Manual Lifting Only

    6 Maintenance 6.2.3 Disassembly - Manual lifting only a) Dismantle the circlip (43.2) and remove the pin (43.1) from the lever (43). b) Pull off the lever (43) from the rod (39) and remove the disc (42). c) Unscrew the hood (25). d) Remove O-ring (24), pressure spring (40) and spring guide (19).

  • Page 39: Technical Data

    7 Technical Data NOTE Technical data must be observed during installation, operation and maintenance. All personnel should be informed about the technical data. 7.1 Technical Data Temperature Temperature range: +4 °C to +95 °C Valve Size DN25-DN100 Connection option Flange or clamp Temperature ambient +4 °C to +45 °C Max.

  • Page 40: Identification

    3. Valve number Order No. #######/## 4. Manufacturer number MM/YYYY Valve No. ########## 5. Size AISI 316L Type No. 6357########### 6. Coefficient of discharge (L = Liquid) Size DN ### #### mm² #.# bar 7. Temperature #.## -L, Lift #.## mm #.## -G...

  • Page 41: Setting Range

    Technical Data 7 7.5 Setting range Nominal pipe size Setting range Narrowest flow area Inlet Outlet α-value α-value Seal: EPDM [bar] [mm] [mm] [mm] (liquid) (gas) 0.2-0.9 0.38 0.43 1.0-1.5 0.41 0.43 1.6-2.0 0.42 2.1-2.5 0.44 DN25 2.6-3.0 0.41 3.1-4.5 0.47 4.6-7.0 0.45...

  • Page 42: Dimensions

    7 Technical Data 7.6 Dimensions 2001-0024 2001-0025 Standard Standard DN25 DN40-DN100 Size DN25 Rd52x1/6 Rd58x1/6 DN40 Rd65x1/6 Rd65x1/6 DN50 Rd78x1/6 Rd78x1/6 DN65 Rd95x1/6 Rd95x1/6 DN80 Rd110x1/4 Rd110x1/4 407.5 DN100 Rd130x1/4 Rd130x1/4 28.2 200007932-2-EN-GB...
  • Page 43 Technical Data 7 2001-0026 2001-0027 Standard with inductive sensor Standard with inductive sensor DN25 DN40-DN100 Size DN25 Rd52x1/6 Rd58x1/6 DN40 Rd65x1/6 Rd65x1/6 DN50 Rd78x1/6 Rd78x1/6 DN65 Rd95x1/6 Rd95x1/6 DN80 Rd110x1/4 Rd110x1/4 407.5 DN100 Rd130x1/4 Rd130x1/4 28.2 200007932-2-EN-GB...
  • Page 44 7 Technical Data 2001-0022 2001-0023 Pneumatic lifting with inductive sensor Pneumatic lifting with inductive sensor DN25 DN40-DN100 Size DN25 Rd52x1/6 Rd58x1/6 DN40 Rd65x1/6 Rd65x1/6 DN50 Rd78x1/6 Rd78x1/6 DN65 Rd95x1/6 Rd95x1/6 DN80 Rd110x1/4 Rd110x1/4 407.5 DN100 Rd130x1/4 Rd130x1/4 28.2 200007932-2-EN-GB...
  • Page 45 Technical Data 7 2001-0020 2001-0021 Manual lifting Manual lifting DN25 DN40-DN100 Size DN25 Rd52x1/6 Rd58x1/6 141-182 DN40 Rd65x1/6 Rd65x1/6 152-232 10.3 DN50 Rd78x1/6 Rd78x1/6 154-234 15.5 DN65 Rd95x1/6 Rd95x1/6 153-233 16.2 DN80 Rd110x1/4 Rd110x1/4 407.5 152.5-232.5 23.2 DN100 Rd130x1/4 Rd130x1/4 152-232 29.6 200007932-2-EN-GB...
  • Page 46 7 Technical Data 2001-0037 2001-0038 2001-0039 2001-0040 Standard with inductive Pneumatic lifting with in- Standard sensor ductive sensor Manual lifting 200007932-2-EN-GB...

  • Page 47: Spare Parts

    Alfa Laval representative for availability. You can find our spare part catalogue at https://hygienicfluidhandling-catalogue.alfalaval.com. Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts. 8.1 Ordering Spare Parts When ordering spare parts, please always state: 1.

  • Page 48: Warranty - Definition

    8.3 Warranty - Definition WARNING The rules of Intended use are absolute. Use of the supplied Alfa Laval product is allowed only when in compliance with the technical data supplied with the Intended use. Differing utilisation, other than agreed with Alfa Laval Kolding A/S, exclude any liability and warranty.

  • Page 49: Parts Lists And Exploded Views

    9 Parts Lists and Exploded Views 9.1 Standard DN25 DN40-DN100 2001-0030 2001-0029 Pos. Qty. Denomination Pos. Qty. Denomination Body Plain bearing Screw-in socket Cover plate Slotted nut O-ring Piston plate O-ring Piston O-ring Plain bearing Shaft sealing Spring disc O-ring Distance ring Hood Spring guide...

  • Page 50: Standard With Inductive Sensor

    9 Parts Lists and Exploded Views 9.2 Standard with Inductive Sensor DN25 DN40-DN100 2001-0032 2001-0031 Pos. Qty. Denomination Pos. Qty. Denomination Body O-ring Screw-in socket O-ring Slotted nut O-ring Piston plate Shaft sealing Piston O-ring Plain bearing Hood Spring disc 25.1 Hood incl.

  • Page 51: Pneumatic Lifting With Inductive Sensor

    Parts Lists and Exploded Views 9 9.3 Pneumatic Lifting with Inductive Sensor DN25 DN40-DN100 2001-0034 2001-0033 Pos. Qty. Denomination Pos. Qty. Denomination Body O-ring Screw-in socket O-ring Slotted nut O-ring Sealing Shaft sealing Sealing O-ring Piston plate Hood Piston 25.1 Hood incl.

  • Page 52: Manual Lifting

    9 Parts Lists and Exploded Views 9.4 Manual Lifting DN25 DN40-DN100 43.2 43.1 43.2 43.1 2001-0036 2001-0035 Pos. Qty. Denomination Pos. Qty. Denomination Body O-ring Screw-in socket O-ring Slotted nut O-ring Piston plate Shaft sealing Piston O-ring Plain bearing Hood Spring disc Screw plug - deaeration Spring guide...

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