instruction manual · 2018. 2. 9. · alfa laval cannot be held responsible for incorrect...

2509-0026

ESE02293-EN3 2014-12

Original manual

Instruction Manual

Unique DV-P UltraPure - Pneumatic: for valve sizes DN15-DN50

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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 .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. General information .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.1. General information .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2. Valve design .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. Safety ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.1. Important information .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.2. Warning signs .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.3. Safety precautions .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4. Installation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.1. Unpacking/delivery . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.2. General installation .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94.3. Installation angle of self-draining position .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.4. Drainability . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.5. Welding .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104.6. Recycling information .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5. Operation ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.1. Operation .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6. Maintenance .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136.1. Replacing the diaphragm ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

7. Technical data ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197.1. Control modes ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197.2. Maximum working pressures ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207.3. Technical data .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8. Spare parts and service kits . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228.1. Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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1 EC Declaration of Conformity

The Designated Company

Alfa Laval Kolding A/SCompany Name

Albuen 31, DK-6000 Kolding, DenmarkAddress

+45 79 32 22 00Phone No.

hereby declare that

Diaphragm ValveDesignation

Pneumatical

Type

From serial number Q000001 - Q999999

is in conformity with the following directive with amendments:

- Machinery Directive 2006/42/EC- Regulation (EC) No 1935/2004- Pressure Equipment Directive 97/23/EC category 1 and subjected to assessment procedure Module A

According to the Pressure Equipment Directive PED 97/23/EG, complete valves DN 25 – DN 50 will be certified. Attention:Single components, spare parts and complete valves from DN 15 – DN 20 may not be certified. Single components and spareparts have to be approved by the end user after completion.

The person authorised to compile the technical file is the signer of this document

QHSE Manager, Quality, Health and safety & Environment Annie DahlTitle Name

Kolding 2013-08-01Place Date Signature

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2 General information

2.1 General information

The compact diaphragm valve is low maintenance, has apneumatic actuator and is available in the normally closed,normally open and air/air modes of operation.

We highly recommend additional test(s) for any knownspecial operating conditions. The customer is responsiblefor carrying out these tests.

The pneumatic actuator is available as a completecomposite version. The actuator is dimensionally reducedto a minimum and is especially suited to applications wherespace is limited.

This valve is not to be used in areas when aromatichydrocarbons, such as Benzene, Toluene, Xylene or higherAlkylbenzene are present or are the main part of organicsteams because the nameplate will not withstand thesemediums. Should the valve be installed in such areas, thenameplate must be changed.

A wide range of accessories such as an electrical feedbackunit, positioner, BUS systems or stroke limiter, allow optimaladaption to all types of control tasks.

The hazards caused by chemical reactions between partsof the valve and the chemical mediums used have to beclarified between the manufacturer and customer.

Please note that the valve includes a diaphragm, whichmay load electrostatically depending of the flow medium.

For operating conditions and installation, EN 60079-14must be taken into consideration.The valve has to be integrated into the potential equalisationsystem.

Selection of the diaphragm with regard to the medium andtemperatureis therefore the responsibility of the customer.

As the valve does not generate any heat according toEN 13463-1 para 14.2 g, it is not necessary to display atemperature class sign with regard to surface temperature.

The defined maximum surface temperature depends onthe operating conditions, which are the responsibility ofthe customer. If the valve is used outside the range of theambient temperature and/or the process pressure, thismanual is to be used as a guideline.

These valves are intended to close the medium (on/off orcontrol) after installation into a pipeline. These valves arenot to be used for applications other than those mentioned.

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2 General information

2.2 Valve design

1. Actuator1.1. Indicator pin2. Glide ring (DN40 + DN50 only)3. Housing nut4. Inner housing*5. Mounting nut6. Nut7. Compressor8. Diaphragm holder

15. Diaphragm16. Valve body17. Locking device18. Screw19. Indicator cap

2509-0065

161718

15

7

8

6

5

1

1.1

*4

19

2

3 * = Grease:Alfa Laval recommends: Klüber Paraliq GTE 703


3 Safety

Unsafe practices and other important information are indicated in this manual.Warnings are emphasised by means of special signs.

3.1 Important information

Always read this manual before using the valve!

WARNINGIndicates that special procedures must be followed to avoid serious personal injury.

CAUTIONIndicates that special procedures must be followed to avoid damage to the valve.

NOTEIndicates important information to simplify or clarify procedures.

3.2 Warning signs

General warning:

Caustic agents:


3 Safety

All warnings in the manual are summarised on this page.Pay special attention to the instructions below so that serious personal injury and/or damage to the valve are avoided.

3.3 Safety precautions

Installation:

Always read the technical data thoroughly (See chapter 7 Technical data)Always release compressed air after useNever touch the moving parts if the actuator is supplied with compressed airNever touch the valve or the pipelines when processing hot liquids or when sterilisingNever dismantle the valve with the valve and pipelines under pressureNever dismantle the valve when it is hot

Operation:

Never dismantle the valve with the valve and pipelines under pressureNever dismantle the valve when it is hotAlways read the technical data thoroughly (See chapter 7 Technical data)Always release compressed air after useNever touch the valve or the pipelines when processing hot liquids or when sterilisingNever touch the moving parts if the actuator is supplied with compressed airAlways rinse well with clean water after cleaning

Always handle lye and acid with great care

Maintenance:

Always read the technical data thoroughly (See chapter 7 Technical data)Always release compressed air after useNever service the valve when it is hotNever service the valve with the valve and pipelines under pressureNever put your fingers through the valve ports if the actuator is supplied with compressed airNever touch moving parts if the actuator is supplied with compressed air

Transportation:

Always make sure that compressed air is releasedAlways check that all connections are disconnected before attempting to remove the valve from the installationAlways drain liquid from valves before transportationAlways ensure that the valve is adequately secured during transportation - if specially designed packaging material isavailable, it must be used


4 Installation

The instruction manual is part of the delivery. Study the instructions carefully.The items refer to the parts list and service kits section.The valve is supplied as separate parts as standard (for welding).The valve is assembled before delivery, if it is supplied with fittings.

4.1 Unpacking/delivery

Step 1CAUTIONAlfa Laval cannot be held responsible for incorrect unpacking.Check the delivery for:1. Complete valve.2. Delivery note.

Step 21. Remove any packing materials from the valve/valve parts.2. Inspect the valve/valve parts for visible transportation damage.3. Avoid damaging the valve/valve parts.

4.2 General installation

Step 1

Always read the technical data thoroughly.

CAUTIONAlfa Laval cannot be held responsible for incorrect installation.

Avoid stressing the valve.Pay special attention to:- Vibrations.- Thermal expansion of the pipelines.- Excessive welding.- Overloading of the pipelines.

!

2509-0028

Risk of damage!

- For draining the diaphragm valve and pipeline, the appropriate installation position has to be provided.- For the variable installation position for self-draining, see data on the installation angle.- For diaphragm valves with weld ends, remove the actuator and diaphragm from the valve body before welding


4 Installation

Study the instructions carefully and pay special attention to the warnings!The valve has welding ends as standard but can also be supplied with fittings.

4.3 Installation angle of self-draining position

Step 1Drain angle x

Forged bodies DIN 11866 Series C ASME BPE

DN v Drain angle x

15 ½” 37°

20 ¾” 22°

25 1” 30°

40 1 ½” 24°

50 2” 20°

2509-0068

X°

4.4 Drainability

To ensure proper drainability, the valve must be mounted at the correct angle.Proper installation is the responsibility of the system installer and/or user.See above table.

4.5 Welding

Step 1All welding should be done by qualified personnel.Disassemble the actuator from the valve body.

Step 2Perform the welding procedure on the body according to standard industrial practices.

Step 3Reassemble the actuator with diaphragm to the valve body.

Step 4Test the valve for correct operation before installing.


4 Installation

Study the instructions carefully and pay special attention to the warnings!The valve has welding ends as standard but can also be supplied with fittings.

4.6 Recycling information

• Unpacking

- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps- Wood and cardboard boxes can be re-used, recycled or used for energy recovery- Plastics should be recycled or burnt at a licensed waste incineration plant- Metal straps should be sent for material recycling

• Maintenance

WARNING!!: Opening the NO actuators can be dangerous because of compressed springs

- During maintenance, oil and wear 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 of in accordance with local regulations

• Scrapping

- At end of use, the equipment must be recycled according to relevant, local regulations. Besides the equipment, anyhazardous residues from the process liquid must be taken into consideration and dealt with in a proper manner. When indoubt, or in the absence of local regulations, please contact your local Alfa Laval sales company


5 Operation

Study the instructions carefully and pay special attention to the warnings!Ensure that the valve operates smoothly.The items refer to the parts list and service kits section.

5.1 Operation

Always read the technical data thoroughly.See chapter 7 Technical data

Always release compressed air after use.

CAUTIONAlfa Laval cannot be held responsible for incorrect operation.

Function NC: Normally closed

In the de-energised status, the valve is closed by a spring force. When the control medium is admitted to the actuator(connection below), the valve opens; when the control medium escapes, the valve is closed by the spring force.

Function NO: Normally open

In the de-energised status, the valve is opened by a spring force. When the control medium is admitted to the actuator(connection above), the valve closes; when the control medium escapes, the valve is opened by the spring force.

Function A/A: Air/Air (double acting)

The valve has no defined basic position. The valve is opened and closed by applying control pressure to the correspondingcontrol connection. Connection below: open, connection above: close.


6 Maintenance


6.1 Replacing the diaphragm

Generally, the only routine maintenance required is the replacement of the diaphragm. The diaphragm replacement routine,depending on the medium, pressure, temperature and cycle (duration and temperature) of steam sterilisation between processruns, determines the optimum change cycle of the diaphragm.

As with all diaphragm valves, the diaphragm itself is the strongest component used. In addition to mechanical stress, thediaphragm is subject to wear resulting from the flow media.

If the flow medium is muddy or contains abrasive particles, we recommend more frequent inspections. The diaphragm can bechecked by dismantling the valve body.

We recommend maintenance of the actuator at the latest after 250,000 cycles. Please contact Alfa Laval.

Before servicing any installed valve, you must:- depressurise the system- open the valve- purge the valve

Note: The diaphragm can be replaced without removing the valve body

Step 1Only use Alfa Laval diaphragms

Step 2Actuate the valve to the “open” position for:- NC and A/A actuators, apply air pressure of the lower actuator port- NO actuators, relieve the air pressure of the upper actuator port

Note:Indicator pin will show fully open position.

2509-00462509-0047


6 Maintenance


Step 3Unfasten the housing nut by turning it anti-clockwise.Use a strap wrench or our special tool to easy it until you can turn it manually.

2509-0066

2509-0048

Step 4Remove the actuator.

Step 5Actuate the actuator to the “closed” position.

Step 6Hold actuator tight and screw the diaphragm anti-clockwise out of the inner housing.Note:Compressor is loose and can fall out.

2509-0049 2509-0050


6 Maintenance


Step 71. Mount/replace the correct locking device/diaphragm indicator

(white => PTFE / black => EPDM) into the slot of the valve body.2. Secure with the screw.

2509-0037

Step 8Place the compressor into the inner housing.

2509-0051

Step 9Check and clean the thread in the diaphragm holder.

Step 10Ensure that the new diaphragm and the contact area on the valve body are clean and dry.


6 Maintenance


Step 11Hold the actuator tight. Screw new diaphragm hand tightclockwise into the compressor.

Note!Always use new diaphragms after disassembling the valve.

2509-0052

Step 12Turn it min. 90° counter clockwise as far as the tabs placedbetween the guiding bars of the inner housing. The correctposition is reached when the tab is aligned with the large rib ofthe inner housing

2509-0053

Step 13Actuate the valve to the “open” position (see Step 2)


6 Maintenance


Step 14Align the actuator to the valve body so that the guiding bars andtabs of the diaphragm fit the slots in the valve body.

2509-0054

Step 15Turn the housing nut clockwise manually until it is hand tight.

2509-0055

Step 16Important!Open and close the actuator 2-3 times to ensure that the diaphragm fits into the valve seat.


6 Maintenance


Step 171. Use a strap wrench or our special tool to help to turn the housing nut to the closed position.2. Turn the housing nut clockwise until the arrows are aligned with the centre of the tubes.Note:The square mark on the housing nut must be aligned with the screw in valve body.

2509-0067

2509-0056

2509-0057


7 Technical data

It is important to observe the technical data during installation, operation and maintenance.Inform personnel about the technical data.

7.1 Control modes

a) Function NC: normally closed with a solenoid valve3/2-way for connection below

Fig. a

P R

A

TD 456-164

b) Function NO: normally open with a solenoid valve3/2-way for connection above

Fig. b

TD 456-165

P R

A

c) Function A/A: air/air with a solenoid valve 4/2 and5/2-way for connection below and above

Fig. c

5 1 3

P

4 2

TD 456-166


7 Technical data


7.2 Maximum working pressures

Table 1. Actuator NCMax. working pressure at 23° C (73° F) medium temperature

EPDM PTFESize

DN InchGr.

bar psi bar psiGr.

bar psi bar psi

15 (½”) 1 10 145 10 145 2 10 145 10 145

20 (¾”) 2 10 145 10 145 2 10 145 10 145

25 (1”) 2 10 145 10 145 3 10 145 10 145

40 (1½”) 4 10 145 10 145 5 10 145 10 145

50 (2”) 4 10 145 10 145 5 10 145 10 145

Table 2. Actuator NO, AAMax. working pressure at 23° C (73° F) medium temperature

EPDM PTFESize

DN InchGr.

bar psi bar psiGr.

bar psi bar psi

15 (½”) 1 10 145 10 145 2 10 145 10 145

20 (¾”) 2 10 145 10 145 2 10 145 10 145

25 (1”) 2 10 145 10 145 2 10 145 10 145

40 (1½”) 4 10 145 10 145 4 10 145 10 145

50 (2”) 4 10 145 10 145 4 10 145 10 145

Working pressure on one sideWorking pressure on both sides

NO/AA measuring with 5 bar (72.5 psi) control pressure


7 Technical data


7.3 Technical data

Pressure

Min. product pressure Full vacuum

Max. product pressure 1000 kPa (10 bar)

Pneumatic operation

Actuator function NC, NO and A/A

Max. pressure 6 bar (NC), 5 bar (NO / A/A)

Max. control air temperature 50°C

Control air Compressed air (oil-free) inert, non-aggressive gases

Air connection

Actuator sizes 1-3 G1/8”

Actuator sizes 4-5 G1/4”

Optical positioner √

Interchangable control function

Adjustable spring pressure √Autoclavable √ (121°C, 60 min.)

Manually operated

Optional positioner √Lockable √Autoclavable √ (121°C, 60 min.)

Temperature

Temperature range -5°C to +95°C (150°C continuous steam)

Materials

Valve body AISI 316L (1.4435)Delta ferrite < 0.5 %Sulphur content 0.005-0.017%

Clamp ferrule AISI 316L (1.4404)

Actuator PPS GF40

Handle PP GF30/PPS GF40

Diaphragm EPDM and PFTE/EPDM

Surface finish (surface condition according to ASME BPE 2009 table SF-1, SF-2)

Internally Ra ≤ 0.51 µm (SF1)/Ra ≤ 0.38 µm electropolished (SF4)Externally Ra ≤ 1.6 µm


8 Spare parts and service kits


8.1 Actuator

16

15

7

6

8

5

4

3

1

2509-0020

17

18

19

132


8 Spare parts and service kits


Parts list

Pos. Qty Denomination

1 1 Actuator2 1 Glide ring (DN40 + DN50 only)3 1 Housing nut4 1 Inner housing5 1 Mounting nut6 1 Nut7 1 Compressor8 1 Diaphragm holder13 1 Actuator15 ♦ 1 Diaphragm16 1 Valve body17 ♦ 1 Locking device18 ♦ 1 Screw19 1 Indicator cap

Service kits

Denomination½”DN15

3/4”DN20

1”DN25

1½”DN40

2”DN50

♦ Diaphragm set, EPDM (incl. Q-doc) . . . . . . . . . 9615-0224-01 9615-0224-02 9615-0224-03 9615-0224-04 9615-0224-05♦ Diaphragm set, PTFE/EPDM (incl. Q-doc) . . . 9615-0224-06 9615-0224-07 9615-0224-08 9615-0224-09 9615-0224-10

Parts marked with ♦ are included in the diaphragm set

TD 900-630


How to contact Alfa LavalContact details for all countries arecontinually updated on our website.Please visit www.alfalaval.com to access the information directly.

© Alfa Laval Corporate ABThis 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 thisdocument 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 anyform or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate ABwill enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.


toc2.1General information 2.2Valve design

3.1Important information 3.2Warning signs 3.3Safety precautions

4.1Unpacking/delivery Check the delivery for:4.2General installation 4.3Installation angle of self-draining position 4.4Drainability 4.5Welding 4.6Recycling information

5.1Operation 6.1Replacing the diaphragm Before servicing any installed valve, you must:

7.1Control modes 7.2Maximum working pressures 7.3Technical data

8.1Actuator Service kits

tablesTable 1. Actuator NCTable 2. Actuator NO, AA

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instruction manual · 2018. 2. 9. · alfa laval cannot be held responsible for incorrect...

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