Double Seat Valve DELTA D2 - Alliance Fluid Handling · 2017. 9. 8. · sealing material, the DELTA D2 double seat valve can be used in the food and beverage as well as in the pharmaceutical

Double Seat Valve

DELTA D2

Operating Manual

Rev. 4

michael.sunder

OBSOLETE

1. General Information

2. Safety Instructions

3. Operation

4. Additional Equipment

5. Cleaning

6. Installation

7. Maintenance

8. Fault Clearance

9. Materials

10. Dimensions / Weights

11. Technical DataClosing Times - RN 260.36Kvs / Cv-Values - RN 260.33 , RN 260.31-1Pressure Drops - RN 260.33 , RN 260.33-1

- RN 260.33-2 , RN 260.33-3

12. Assembly InstructionsAssembly Tool for Seat Seal- RN 260.38

13. Spare PartsD2 - DIN-Sizes - RN 01.053.0D2 - Imperial Inch Sizes - RN 01.053.05D2 - Sh5 -Sizes - RN 01.053.07Actuator - RN 01.053.2-2

C o n t e n t s

1Double Seat Valve Delta D2Operating Manual : Rev.4

The operating manual has to be read and observed by the competent operating and maintenance personnel.

We wish to point out that we do not accept any liability for any damageor malfunctions resulting from the non-compliance with the operatingmanual.Descriptions and data given herein are subject to technical changes.

2. Safety Instructions

Danger !

- Before starting maintenance work, any pressure source in the pipe and cleaning system must be switched off !

- Risk of injury by suddenly actuating valve !

- Observe assembly instructions to ensure safe maintenance of valve!

- During operation and seat lifting operating leakage will spray out downwards (F) !

- If CIP connection (D) is not used, it should be sealed by a plug !

- Spring tension in the actuator, do not open it by force!

3. Operation

Thanks to the use of high-grade stainless steel and the corresponding sealing material, the DELTA D2 double seat valve can be used inthe food and beverage as well as in the pharmaceutical andchemical industries.

- The valve opens from the top to the bottom.

- Separation of two fluid flows by two independent valve seats withcleanable leakage chamber between them, CIP connection at (D).

- Double seal function by two seals acting independently of each other.

- Any leakages arising at the valve seats are discharged to theatmosphere in depressurized state at (F).

- A valve feedback switch can be mounted at (E).

- Operation by pneumatic actuator with air connection at (C).Reset by spring force.

1. General Information


- The double seat valve is generally fitted with an actuator spring toclose (FH). If the air supply fails, the valve moves into the safety position “closed”.

.

- The inner parts of the actuator are maintenance-free.

- To clean the valve seats, a seat lift actuator (H) is mounted on top ofthe main actuator.

seat lift actuatorconnection A = lifting of lower valve seatconnection B = lifting of upper valve seat

Valve in closed position

Upper and lower valve seats are closed and separated by the leakagechamber being open to the atmosphere. In this position two separate fluid flows (pipelines A and B) can pass through the valve without any cross contamination.

Valve in open position

The upper valve seat moves against the lower one and presses it out of its seat.The lower seat seal seals off the leakage chamber (L) and separates it from the product chamber. In this position the fluid flows (pipelines A and B) are open to each other.

3. Operation

3Double Seat Valve Delta D2

Operating Manual : Rev.4

* Seat lift actuator

If necessary for process engineering or biological reasons, the DELTA D2 valve can be fitted with a seat lift actuator.(See operating manual "Seat Lift Actuator for DELTA D2 DoubleSeat Valve".)

* Valve feedback switchesSwitches to feed back the final positions of the valve seats can beinstalled in the yoke area if required (See chapters 3 and 12.5. f).

* We recommend to use one of our APV standard types.Operating distance : 5 mm / diameter : 11 mm .If a different valve position indicator is provided by the customer,we cannot take over any guarantee for a faultless function.

* Installation of a control unit with microswitches or proximity switchesand solenoid valve on top of the actuator is possible.(See operating manual "Control Unit for DELTA D2 Double Seat Valve".)

* Moreover, the assembly of the intelligent control system “Valve Net”(field bus technology) is also possible.

* Centering pinsThese pins are required to facilitate the installation of the valve insert.(See chapters 12. 12.5 and 7)

* Assembly tool for seat sealsIn order to ensure a correct fit of the seat seals, assembly tools according to RN 260.38 are available.Assembly instructions see page 17.Corresponding tool sizes see chapter 12, RN 260.38.

5. Cleaning

With the cleaning of double seat valves, different areas have to be considered which are,

- the flow chambers, i.e. the upper and lower passage,

- the seal seats and

- the leakage chamber.

The flow chambers are cleaned during the cleaning of the connected pipes by the passing cleaning liquids.

The seal seats are cleaned during valve operation and by lifting of the individual seats during the cleaning of the corresponding passage. The seal areas are flushed by the cleaning liquid.

The leakage chamber is particularly cleaned via the CIP connection,but also by passing cleaning liquids during the operation of thevalve or during seat lifting.

4. Additional equipment


Cleaning of the valve body as well as of the leakage chamber depends on the general cleaning cycle of the plant.

The valve is cleaned together with the tanks and pipes.CIP of the leakage chamber as well as seat lifting are controlledautomatically.

Seat lifting

The valve seats are lifted out of their seats by means of the seat lift actuator mounted on top of the main actuator. The seat lift actuator is equipped with two actuating pistons with corresponding air connections, the upper one (A) for the lower valve seat and the lower one (B) for the upper valve seat lifting.

- Assembly and adjustment of the seat lift actuator (see operating manual "Seat Lift Actuator for Delta D2 Double Seat Valve").

Upper valve seat area

The upper valve seat is preliminarily opened by the seat lift actuator.Cleaning liquid flushes the upper seal and seat area (X) as well asthe leakage chamber (L).

Lower valve seat area

The lower valve seat is preliminarily opened by the seat lift actuator.Cleaning liquid flushes the lower seal and seat area (Y) as well asthe leakage chamer (L).

Within a valve manifold max. 4 valve seats in a row can be liftedvia one solenoid valve in the control air line.

CIP of leakage chamber

The hose connection (D) for cleaning the leakage chamber issituated at the valve shaft in the yoke area.

The pressure of the cleaning liquids and their supply (3 bar min. at5 to 10 l/minute) ensure a biologically perfect cleaning of the complete leakage chamber.

5. Cleaning



Depending on the product handling, the leakage chamber must becleaned at least once a day.

Several valves can be cleaned simultaneously via one CIP distribution pipe.

Under normal circumstances max. 15 valves are cleaned via one CIP distribution pipe DN 25. The quantity of valves to be cleaned is independent of their size.

CIP recommendations (not binding)

The CIP program should be adapted to the product to be handledand to the specific application.

Common CIP methods are e.g.

cold CIP with caustic and / or acid ambient temperature

hot CIP with caustic (80 °C to 90 °C)

In general, tank cleaning is done with cold and pipe cleaning is done with hot liquid.In general there is a cold tank CIP and a hot pipe CIP.

Table 1 provides a survey of the recommended standard CIP programs.

Table 1: Standard CIP program,recommended times in minutes

)* without change of liquid, i.e. admittance time of every section of the installation to the flushing liquid without possible mixing with thepreceding fluid,

)** tank cleaning

The composition of the individual cleaning liquids depends on thetype of the production process, the detergents selected and the related recommendations of their manufacturers.

5. Cleaning

6

Program tep Cleani ngcol d hot

preflushi ng ) * 2 (20) ** m inutes 2 m inutescleaning 45 ) ** m inutes 30 m inutesinterm ediate flushi ng ) 2 m inutes 2 m inutesdisinfect ion 30 m inutes 30 m inutes

Double Seat Valve Delta D2Operating Manual : Rev.4

During the individual cleaning steps in the upper and/or lower valve passage the leakage chamber and the seat surfaces have to be cleaned at a certain interval (period) in several impulses in quick succession (number) each of a certain duration as per recommendation in table 2.

Table 2: Standard cleaning, recommendation for seat lifting and CIP spraying.

)* depending on pressure ratio, with lower pressures also longer in individual cases

During tank cleaning (cold) the upper seat lifting is actuated, while CIP of the leakage chamber takes place independently of this during the cleaning of pipes.

6. Installation

- Installation must be in vertical position to enable liquids to drainoff the valve body and leakage chamber.

- Valves can be welded directly into the pipeline (completelydismantable valve insert).

- Installation and dismantling heights and space requirements fordrip trays, etc. (see chapter 10).

Attention: Observe welding instruction !

5. Cleaning

7

Control Period Num ber Duration in sec.

of cycl es inm inutes

of respect ive cont rol (s)

seat lifting 5 3 to 5 1 - 2 ) *CIP spr aying 5 3 to 5 3 ) *


D2

- Before welding of the valve, the valve insert and the lower shaft seal must be dismantled from the housing. A careful handlingwithout damage to the parts must be provided.

- Welding may only be carried out by certified welders (EN 287-1).(Seam quality EN 25817 „B“).

- The welding of the valve housings must be effected in such a way that deformation strain cannot be transfered to the valve body.

- The preparation of the weld seam up to 3 mm thickness must be carried out in butt manner as a square butt joint without air.(Consider shrinkage!)

- TIG orbital welding should be aimed at!

- After welding of the valve housing or of the mating flanges and after work at the pipelines, the corresponding parts of the installation or pipelines must be cleaned from welding residues and soiling.If these cleaning instructions are not observed, welding residues and dirt particles can settle in the valve and cause damage.

- Any damage resulting from the nonobservance of these welding instructions is not subject to our guarantee.

7. Maintenance

- The maintenance intervals depend on the application of the valve and should be determined by the user himself after some regularchecks.

- Exchange of seals according to assembly instructions.

RN scheet 260.38.

6.1 Welding Instructions


9

- Insert seat seal with APV seat seal assembly tool according to RN sheet 260.38.

- Lightly grease all seals before their installation.

Recommendation:

APV-food-grade grease for EPDM, Viton and HNBR(0,75 kg/can - Ref.-No. 000 70-01-019/93)(60 g/tube - Ref.-No. 000 70-01-018/93)

o r

APV-food-grade-grease for Silicone(1 kg/can - Ref.-No. 000 70-01-017/93)(40 g/tube - Ref.-No. 000 70-01-016/93)

! Do not use grease containing mineral oil with EPDM seals.! Do not use Silicone based grease with Silicone seals.

- Assembly of valve according to assembly instructions.

- Install valve insert into housing by using centering pinsDN 25 - 65 / 1T-3T ref-no. 67-13-110/12 2 offDN 80 -150 / 4T-6T ref-no. 67-13-111/12 2 off

8. Fault Clearance

Item numbers in accordance with spare parts drawings.Removal of fault - see chapter: assembly instructions.

Valve position closed - : - Replace seat seal ( 4 or 5 ) of leakage from lower valve shaft valve seat under pressure while

leakage occurred.- Check control of CIP spraying,

function of control of seat liftactuator.

Valve position open - : - Replace seat seal (4) of lowerleakage from lower valve shaft valve seat.

Leakage from atmospheric vent : - Replace lower housing hole (see chapter 3, L) seals (18).

Leakage between housing and : - Check upper housing seal (18)yoke flange and upper shaft seal (7) and

replace damaged seal.

Leakage at lower valve shaft : - Replace shaft seal (21).

Leakage at upper valve shaft : - Replace shaft seal (7).

7. Maintenance


Leakage of air at actuator rod : - Replace O-ring at upper sideof actuator.

Actuator does not work (air : - Replace actuator.leaks continuously through Do not try to openventing plug) actuator by force

- spring tension - !

Valve feedback switch does not : - Make fine adjustment.work or works only inaccurately

Valve does not open completely : - Check pressure in lowerand tends to pulsate housing

(max. pressure see chapter 11).

9. Materials

housing, valve seats, shafts 1.4571, 1.4404

actuator, yoke, guide rod, bolts 1.4301

cam PA 12

seals standard: EPDMoptionally: Silicone, Viton

air connections, CIP connection, PA 6.6actuator cover


8. Fault Clearance


W eight s in Kg

DN Tube Sh 5 w ith seat liftact uat or

w ithout seat liftatuat or

25 1 T 9,7 7,040 1,5 T 1,5 10,6 7,950 2 T 2 11,9 9,265 2,5 T 2,5 16,2 13,5

3 T 3 18,2 15,580 18,9 16,2

100 4 T 4 26,7 23,2125 43,1 36,3150 6 53,3 46,5

11


Data in m m

DN

Awith

seat liftact uator

Awithoutseat liftact uator

B ˘̆ D F H Lwith

seat liftact uator

Lwithoutseat liftact uator

st roke

25 470 371 73 26 50 43 559 487 2440 476 377 79 38 67 55 610 511 2450 482 383 85 50 72 67 634 535 2465 490 391 93 66 85 83 666 567 2480 497 398 101 81 98 98 696 597 24

100 507 408 110 100 111 117 734 635 24125 595 484 124 125 130 145 864 753 38150 608 497 136 150 150 170 914 803 38

Tube1,5T 474 375 77 35,1 67 52,1 603 504 242T 481 382 84 47,8 72 64,8 630 531 242,5T 487 388 90 60 85 77 654 555 243T 493 394 97 72,1 90 89,1 679 580 244T 506 407 109 97,6 111 114, 6 730 631 24


12


Inst al lat ion dim ensions in m m

m in .dim ensionsY Y X X

with seatlift act uator

withoutseat liftact uator

withoutdriptray

recom m enddim ensions

with /w ithoutdrip tray

DN Tube Sh 525 1 T 630 530 250 50040 1,5 T 1,5 660 560 260 50050 2 T 2 690 590 270 50065 2,5 T 2,5 720 620 300 600

3 T 3 760 660 310 60080 760 660 320 700100 4 T 4 830 730 350 700125 930 820 400 800150 6 1040 930 450 800

Data in m m

Sh 5

Awith

seat liftact uator

Awithoutseat liftact uator

B ˘̆ D F H Lwith

seat liftact uator

Lwithoutseat liftact uator

st roke

1,5 480 381 82 45,1 67 62,1 624 525 242 486 387 88 57,1 72 74,1 648 549 242,5 492 393 94 68,8 85 85,8 672 573 243 501 402 102 84,9 100 101, 9 705 606 244 513 414 115 110, 3 114 127, 3 756 657 246 616 505 143 163, 1 150 184, 3 943 832 38


13

max. operating pressure = 5 bar (with standard actuator)

max. operating temperature = 140 °C EPDM, HNBRmax. 135 °C Silicone, Viton

sterilization temperature = 150 °C EPDM, HNBRmax. 140 °C Silicone, Viton

tightening moment of safetynut at lower valve shaft = 40 Nm

CIP connection for hose8 x1 mm capacity-cleaning at

3 bar = about 5 to 10 l / minute

air connection for hose 6 x 1 mm control pressure = max. 10 bar

min. 6 bar

! (use dry and clean air only)

11. Technical Data


Standard arrangem ent of act uat or and seat lift act uat or

act uator airconsum pt ion

act uatorin NL / st roke

strokeuppershaf t

st rokelowershaf t

seatlift

act uator

air consum pt ionact uator

in NL / st roke

DN Tube Sh 525 1 T D 100 - 22 2,3 28 24 ˘ 100 0,8

40 1,5 T 1,5 D 100 - 22 2,3 28 24 ˘ 100 0,8

50 2 T 2 D 100 - 22 2,3 28 24 ˘ 100 0,8

65 2,5 T 2,5 D 125 - 22 3,5 28 24 ˘ 100 0,8

80 3 T 3 D 150 - 22 5,0 28 24 ˘ 100 0,8

100 4 T 4 D 180 - 22 7,0 28 24 ˘ 100 1,2

125 D 220 - 22 15,0 42 38 ˘ 100 2,2

150 6 D 255 - 22 20,0 42 38 ˘ 100 2,2

Data in litreLine pressur e 3 bar in upper val ve housi ngLiquid: water t = 20 OC

val ve open val ve closedDN Tube Sh 525 0,1 0,240 1,5 1,5 0,15 0, 3550 2 2 0,2 0,465 2, 5 2,5 0,22 0, 55

3 0,24 0, 6680 3 0,26 0, 7

100 4 4 0,4 1,3125 0,7 1,4150 6 0,9 1,5

14

The item numbers relate to the spare parts listsDIN: RN 01.053.0, imperial inch size: RN 01.053.05,Sh5: RN 01.053.07)

The actuator item numbers relate to spare parts list RN 01.053.2-1

12.1 Dismantling from pipe system

a. Shut off line pressure in the product and cleaning line.

b. Remove CIP connection.

c. Remove control air hose.

d. Loosen locking screw of feedback support and pull off switch.(If a feedback switch is not installed, item 12.1.d does not apply.)

e. Remove flange screws (8).

f. Screw one flange bolt into the tapped hole of the valve yoke which induces the complete valve insert to be lifted.

g. Remove flange screw again and carefully lift valve insert verticallyout of the valve housing.

12.2. Dismantling of wear parts

a. Pull off lower shaft seal (21) from the groove in the housing bottom (1). (Assembly see 12.4.p.)

b. Remove lower and upper housing seals (18) from valve seat (19).(Assembly see 12.4.n.)

c. Loosen safety nut (23). Hold against the lower shaft (2) witha spanner of the same size to prevent it from turning.

d. The nut (23) being removed, the lower shaft (2) can be taken off.

e. Stick a sharp object into the lower seat seal (4) and carefullyremove it from the groove.(Assembly see 12.4.k.)

Caution: For the next step, compressed air of “min. 4 bar”is required. The coupling clamp (13) is under spring tension.

f. Open the valve by supplying air to the actuator.

Danger: Do not touch moving parts!Risk of injury by sudden actuation of the valve.

g. Loosen locking screw of coupling clamp (13) and remove complete coupling.

* Shut off air pressure!

12. Assembly Instructions


15

h. Remove upper valve shaft (3). The cam (16) loosenssimultaneously.

i. Stick a sharp object into the seat seal (5) and carefully remove itfrom the groove. (Assembly see 12.4.g.)

j. Loosen bolt (17) which serves to position the valve seat.Remove valve seat (19) and pull out upper shaft seal (7).(Assembly see 12.4.e.)

k. Remove yellow cap of actuator rod and push out rod (6) towards the actuator (24). Slight tapping by a rubber hammer facilitates work. At the same time, access to the cam (16) is provided.

Caution: If the D2 valve is fitted with a seat lift actuator, it must be removed first before pushing out the rod (6) .(Assembly and disassembly see operating manual"Seat Lift Actuator for Delta D2 Double Seat Valve".)

l. Remove O-rings (14) from cam.(Assembly see 12.4.b)

m. Remove bolts (12) and separate complete actuator from yoke (11).

ActuatorThe item numbers refer to the spare parts list RN 01.053.2-1.

n. Remove lower O-ring (2) of actuator.

o. Remove actuator bolts (4) and cover (3).(If the D2 valve is fitted with a seat lift actuator, item 12.2.ndoes not apply.)

p. Remove upper O-ring (2) of actuator.

12.3. Assembly of actuator

a. Insert greased O-rings (2) over the piston rod into front-sidegrooves on both sides of the actuator.

b. Push actuator cover (3) over the piston rod (air supply side) andfasten it by bolts (4).(If the D2 valve is fitted with a seat lift actuator, item 12.3.b. doesnot apply.)



16

12.4. Installation of seals and assembly of valve

a. Fasten actuator (24) with bolts (12) to the yoke (11).

b. Insert slightly greased O-rings (14) into cam (16).

c. Push guide rod (6) from above - threaded part first - through the actuator (24), cam (16) and valve yoke (19).

d. Push yellow cap (5) onto actuator rod.If the D2 valve is fitted with a seat lift actuator, mount the actuator instead of the yellow cap (see operating manual "Seat Lift Actuator for Delta D2 Double Seat Valve").

e. Push internally greased upper shaft seal (7) into yoke groovefrom below.

f. Move valve seat (19) against yoke (11) and fasten it bypositioning screw (17).

g. Before upper valve shaft (3) is mounted, the upper seat seal (5)must be inserted according to the assembly instructions 12.6.

Caution: In order to connect the upper shaft (3) with the actuator (24),compressed air of “min. 4 bar” is required for the next step.

h. Open the valve by supplying air to the actuator.

i. Push upper shaft (3) - with the coupling groove first - onto the rod (6), through the shaft seal (7) and then through the cam (16) until it reaches the actuator rod.

j. Connect the two shaft ends with coupling clamp (13).

Caution: While fastening it, the spacer tube must be located between the two coupling halves.The coupling screw must not swing into the feedback area.

* Shut off control air pressure.

Danger: Do not touch moving parts !Risk of injury when valve closes.



k. Before the lower valve shaft (2)(2) is mounted, the lower seat seal (4) must be inserted according to assembly instructions 12.6.

l. Push lower valve shaft (2) over the guide rod (6) against the valve seat (19).

m. Tighten safety nut (23) on the rod (6) until it stops.

n. Pull slightly greased housing seal (18) over the valve seat (19)into the grooves. Check correct fit by passing a finger over the seals.

o. Check if positioning screw (17) is fastened properly.

p. Insert internally greased lower shaft seal (21) into the groove of the housing bottom.

* Check the function of the valve by supplying air to the actuator.

Caution: Do not touch moving parts !Risk of injury when valve closes.

12.5. Installation of valve

a. Screw two centering pins (see chapter 4) opposite to each other into the housing flange (see chapter 3, G).

b. Push complete valve insert carefully into the valve housing (1);yoke flange will position itself by the centering pins.

c. Tighten two bolts (8), remove centering pins and replace them by other bolts (8).

d. Fasten bolts (8) crosswise.

e. Mount air hose and CIP connection.

f. Install valve feedback switches.

Basic adjustment:

Push feedback switch into the mounting block until it stops.

Fine adjustment:

If necessary,the switch point can be set more precisely by a slight backward movement of the switches. Observe LEDs of the switchduring adjustment.

Fix switch with clamping bolts.




12.6. Assembly tool for seat seal

The assembly tool consists of:

Item 1 nut Item 3 ring with venting noseItem 2 press part Item 4 body with two slewable

brackets and two free bolts

Installation of the seat seal into the valve shaft

1. Insert valve shaft into the housing in such a way that the seal groove is in the body.

2. Turn the two slewable brackets into the bolts (the shaft is clamped).Then clamp the housing via the slewable brackets into the vice.

3. Lightly grease seat seal.Use food - grade grease by APV, ref.-no. 70-01-007/93,for this purpose.Pull seal on ring with venting nose until it stops(position see sketch ).

4. Insert ring with seat seal into the housing and press it down until it stops noticeably.

5. Insert press part into the housing.Screw on nut and tighten it to metallic stop by means of a spanner.

6. Loosen nut. Remove ring and press part from the housing.

7. Unclamp body from the vice, open slewable brackets and take the shaft out of the housing.Check if seat seal fits exactly into the groove.

Attention: The tool is neither suited for the installation of seals in the upper shafts of DS valves (low leakage design),nor for the installation of seals in D - valves of the nominal diameters DN 25, 1T.

13. Spare Parts

( see annex)



Documents

Double Seat Valve DELTA D2 - Alliance Fluid Handling · 2017. 9. 8. · sealing material, the DELTA D2 double seat valve can be used in the food and beverage as well as in the pharmaceutical