double seat valve delta da3 - alliance fluid handling

Double Seat Valve

DELTA DA3

Operating Manual

Rev. 0

BA DA3 0000002Ident-No.: 179 518

APV Rosista GmbHZechenstrasse 49D-59425 UnnaTel. : + 49 - 2303 1 08 - 0Fax. : + 49 - 2303 1 08 - 210

1. General Terms 2

2. Safety Instructions 2

3. Mode of Operation 2-4

4. Auxiliary Equipment 5

5. Cleaning 6-7

6. Installation 8

7. Dimensions / Weights 9

8. Technical Data 9-10

9. Materials 10

10. Maintenance 11

11. Assembly Instructions 11-14

12. Disassembly and Assembly Tool 15-16(for lower shaft seal and for middle seal)

13. Detection of Seal Damage 17

14. Spare Parts Lists and Lubrication Chart

DA 3 - DN design - RN - 01.053.73

DA 3 - Tube design - RN - 01.053.73-1

DA 3 - Sh5 design - RN - 01.053.73-2

DA 3 - Lubrication Chart - RN - 260.064-1

Table of Conte nts: Page:

1Double Seat Valve DELTA DA3Operating Manual: Rev.0

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

We have to point out that we will not accept any liability fordamage or malfunctions resulting from the non-compliance with this operating manual.

Descriptions and data given herein are subject to technicalchanges.

2. Safety Instructions

DANGER!

- The line and cleaning system must be depressurized and, if possible, discharged before any maintenance of the valve.

- Observe assembly instructions to ensure safe maintenance of the valve.

- Connections which are not used are to be sealed by a plug.

- A safe discharge of the cleaning liquids must be ensured.

- The spring actuator is under spring load, do not open itby force.

3. Mode of Operation

Due to its construction and mode of operation as well as to the use of high quality stainless steel and adequate seal materials, the double seat valve DELTA DA3 is suited for applications in the food and beverage industries as well as in the pharmaceutical and chemical industries.

1. General Terms


- The valve opens from the top to the bottom in low leakage operation (possible discharge of liquid residues from annular gaps in the seat area).

- Separation of two line passages by two balanced andindependently operating valve slides with intervening leakagechamber.

- Arising leakages at the seat seals are discharged at (E) in depressurized state.

- Proximity switches can be installed as valve position indicators.D1 = valve position "closed"D2 = valve position "open" (only with DN 40 - 50, 1,5T - 2T)D3 = valve position "open" (only with DN 65 - 150, 2,5T - 4T)

- An optical indication of the valve position is installed in the upper area.

- Operation by pneumatic actuator with air connection at (B). Reset by spring force into the safety limit position "closed".

B = valve open

- Maintainable actuator (see 11.3).

- The cleaning of the leakage chamber is done via the cleaning connection (C).

- The cleaning of the seat and shaft seal areas is realized byoperation of the air connections:

A1 = lifting of lower shaft

A2 = lifting of upper shaft

Reset by spring force.

3. Mode of operation

3Double Seat Valve DELTA DA3

Operating Manual: Rev.0

optical valve positionindication

seat liftcylinder

maincylinder

actuator

valvehousing

cleaningconnection

drainpipe

Valve in "closed position".

The lower and upper valve shafts are closed by spring force and safely separate the different fluids A and B. The leakage chamber L which is situated between the two valve seats, provides for a free and absolutely depressurized discharge to the bottom. The valve shafts are balanced and, thus, safe against pressure hammers.

Valve in "open" position.

By control of the the actuator, the upper valve seat is pressed against the seal of the lower valve seat. Thus, the leakage chamber L is closed against the product chamber.Then the two valve seats move downwards into the openposition. A connection between the two pipelines A and B is realized.

3. Mode of operation


5

4. Auxiliary Equipment

* Valve position indicationSwitches to signal the limit position of the valve shaftscan be installed at the actuator if requested(page 3).

We recommend our APV standard types:operating distance: 5 mm / diameter: 11 mm.If the customer decides to use valve position indicators other than APV type, we cannot take over the liabilityfor any malfunctions resulting therefrom.

- Control UnitThe installation of a control unit DELTA CU with solenoid valves direct at the actuator for the pneumatic control of the valves ispossible.

- Field Bus:The assembly of the intelligent control system DELTA CU - Valve Net(field bus technology) can also be realized directly.

- Assembly tool for middle sealTo simplify the installation of the middle seal, the followingassembly tools are available.

Dimensions Designation Ref.-No..

DN 40, 50, 65 - D3 - 62 51-13-376/171,5T, 2T, 2,5T, 3T

DN 80, 100 - D3 - 92 51-13-526/174T

DN 125, 150 - D3 - 138 51-13-676/17

Assembly instructions (see page 16).

Double Seat Valve DELTA DA3Operating Manual: Rev.0

6

5. Cleaning

With the cleaning of the DELTA DA3 valve, one has to distinguishbetween three areas:

The flow areasThe upper and lower passages are cleaned by the passingcleaning liquid during the cleaning of the connected pipelines.

The seal surfacesThe seal surfaces of the upper area (shaft seal and upper seat seal) and the lower area (shaft seal and lower seat seal) areflushed and cleaned by the cleaning liquid by lifting of the individual valve shafts during the cleaning of the respective passage.

The leakage chamberThe cleaning of the leakage chamber is done by CIP spraying.CIP cleaning connection (C).The valve shafts being lifted, the CIP liquid also cleans theleakage chamber.

The spraying does not produce pressure build-up in the leakage chamber and can be carried out in closed and in open valveposition. The conduct of the cleaning liquid provides for a biologically perfect cleaning of the whole leakage chamber.

Under normal conditions 15 valves DN 40 - 10010 valves DN 125 - 150 can be cleaned via one spray distribution line DN 25.

Cleaning recommendation:

- The lifting cycles refer to a cleaning pressure of p = 2 - 5 bar.

- Depending on the pressure ratio, cleaning temperatures, cleaning steps and degree of soiling, different cycles must be adjusted.

- Flushing quantities per CIP spraying cycle : about 1.2 ltr. / 10s

- Cleaning pressure at CIP cleaning connection : min. 2 barmax. 5 bar.

Cleaning step Lifting cycle CIP sprayingpre-flushing 3 x 10 sec.caustic flushing 80 °C 3 x 5 sec. 3 x 10 sec.intermediate flushing 2 x 5 sec. 2 x 10 sec.acid flushing 3 x 5 sec. 3 x 10 sec.subsequent flushing 2 x 5 sec. 2 x 10 sec.


cleaningconnection

7

5. Cleaning

Cleaning of upper area

The upper valve shaft is lifted by the connection (A2).

By lifting of the upper valve shaft, the cleaning liquid flushes viathe upper seat seal and the upper valve seat into the leakage chamber and cleans this area. The cleaning liquid is drained off to the bottom in depressurized state.

Simultaneously, the upper shaft seal and the outer surface of the upper valve shaft are cleaned. Then the cleaning liquid is drained off at the inner tube of the lower valve shaft to the bottom.

The lifting stroke is limited by a metallic stop.

Cleaning of lower area

The lower valve shaft is lifted by the connection (A1).

By lifting of the lower valve shaft, the cleaning liquid flushes viathe lower seat seal into the leakage chamber and cleans this area. The cleaning liquid is drained off to the bottom in depressurized state.

Simultaneously, the lower shaft seal and the outer surfaces of the lower valve shaft are cleaned. The cleaning liquid flushes the spray connection and is then drained off to the bottom in depressurized state.

The lifting stroke is limited by a metallic stop.


Flushing quantity in ml per lifting cycle / 5 sec.

8

6. Installation

- The valve must be installed in vertical position. Fluids must,therefore, be freely drainable off the valve housing and the leakage chamber.

- Valve housings can be welded direct into the pipelines (completelydismantable valve insert).

- Attention: Observe welding instructions.

- Heights of installation and dismantling (see chapter 7).

6.1 Welding Instructions

DA3

- Before welding of the valve, the valve insert must be dismantled from the housing. A careful handling without damage to the parts must be provided (see 11.1).To avoid destruction of the lower shaft seal it need not be removed,but remain in the valve housing.

- 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 transferred to the valve body.

- The preparation of the weld seam up to 3 mm thickness must be carried out in butt manner as an 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 to avoid damage to the valves and seals.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.


9

8. Technical Data

max. line pressure : 10 bar

max. operating temperature : 140°C EPDM140°C HNBR

sterilization temperature : bis zu 150 °C EPDM(short-term) 140°C HNBR

tightening moment of stop sleeve and safety nut at upper and lower valve shaft : 40Nm

cleaning connection (for hose) : 8x1mm

air connection (for hose) : 6x1mm

max. pneumatic air pressure : 10 bar

min. pneumatic air pressure : 6 bar

(Use dry and clean air only)

7. Dimensions / Weights

dimensions in mm

installation weightdimensions

min.in kg

DN A B ˘̆ Di F H L ˘̆ G Y Z40 378 120 38 100 63 561 163 200 660 13,750 384 126 50 100 75 585 163 218 680 13,865 392 134 66 100 91 617 163 242 700 14,080 419 146 81 120 106 671 188 274 790 19,2

100 429 156 100 120 125 710 188 303 820 20,3125 507 176 125 150 150 833 236 342 950150 519 189 150 150 175 858 236 392 1010

Tube1,5T 379 118 35,1 100 63 560 163 197 660 13,7

2T 385 125 47,8 100 75 585 163 216 680 13,82,5T 389 131 60 100 85 605 163 233 700 14,0

3T 395 137 72,1 100 97 629 163 251 730 14,24T 428 155 97,6 120 125 708 188 301 820 20,3


ai r

consum pt ion

ai r

consum pt ion

st roke cl osi ng tim es

act uat or

in

seat lift

cyl inder in

in

m m

in

sec.

NL / st roke NL / st roke shaf ts hose lengt h

upper l ow er kvs - val ues in m3 / h upper low er 1m 10m

DN

40 0,9 1,1 0,3 57 46 23 25 30 26 1, 5 2,5

50 1,1 1,3 0,3 120 95 42 45 37 33 1, 5 2,5

65 1,3 1,5 0,3 219 148 69 78 43 39 1, 5 2,5

80 2,3 2,6 0,45 296 200 120 130 48 44 3, 0 4,0

100 2,3 2,6 0,45 505 320 164 170 48 44 3, 0 4,0

125 6,4 7,0 1,1 800* 500* 300 330 54 50 8, 0 8,0

150 6,4 7,0 1,1 1200* 700* 360 380 62 58 8, 0 8,0

Tube

1,5T 0,9 1,1 0,3 47 40 21 24 32 26 1, 5 2,5

2T 1,1 1,3 0,3 100 73 43 46 39 33 1, 5 2,5

2,5T 1,3 1,5 0,3 170 122 59 66 45 39 1, 5 2,5

3T 1,3 1,5 0,3 213 160 71 80 45 39 3, 0 4,0

4T 2,3 2,6 0,45 490 294 150 160 50 44 3, 0 4,0

10

8. Technical Data

9. Materials

product-wetted parts : 1.4571, 1.4404

other parts : 1.4301

sealsstandard : EPDM/PTFEoption : HNBR/PTFE

: Viton/PTFE

actuator : PA 12 GF 30

cleaning connection : PP

* no measuring value


11

- The maintenance intervals are different depending on the application and are to be determined by the operator himselfcarrying out temporary checks.

- For the dismantling of the valve, compressed air is not required.

- Required tools:- 1 x wrench SW13- 2 x wrench SW17- 2 x wrench SW24- disassembly and assembly tool for the lower shaft seal,

ref.-No. 000 53-13-100/17.

- Exchange of seals according to assembly instructions.

- Assembly of the valve according to assembly instructions.

- Provide all seals with a thin layer of grease before their installation.

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

Recommendation for actuator:APV pneumatic grease:(25 ml /tube - ref.-No. 000 70-01-008/93)

11. Assembly Instructions

The item numbers refer to the spare parts list drawingsDIN: RN 01.053.73, Tube: RN 01.053.73-1

Sh5: RN 01.053.73-2

11.1 Dismantling from the line system

a. Shut off line pressure in the product and cleaning line,discharge lines if possible.

b. Remove pneumatic air line.

c. Release nut of proximity switch holder (13) and pull off proximity switch (remove CU if necessary).

d. Remove flange screws (7) from the actuator (8).

e. Screw one flange screw in the threaded hole of the spring actuator,thus resulting in the complete valve insert being lifted. Do not remove the screw, it facilitates the installation of the valve insert.

f. Carefully pull the valve insert vertically off the valve housing.

10. Maintenance


12

11.2 Dismantling of the product-wetted seals (servicing)

a. Remove the lower and upper housing seal (32) from thevalve seat (6).

b. Release the lower safety nut (42). By holding the lower shaft (3)by a wrench SW17, it is prevented from being turned.

c. The nut being removed, the lower shaft can be lifted.

d. Prick into the middle seal (38) by means of a peaked object andpull it off the groove.

e. Turn off the stop screw (11).

f. Pull guide rod (4) off to the top and remove the O-ring (31).

g. Turn off the safety nut (16). By holding the safety disc (17) by a wrench SW24, it is prevented from being turned.

h. Lift actuators (9, 10) and spring cylinder (8).

i. Press the upper valve shaft (5) with seat ring (37) off the valve seat (6) to the bottom.

j. Pull the seat ring via the compensating piston of the upper valve shaft.

k. Take the seat seals (36) off the groove.

l. The upper shaft seal (33, 34) is removed as follows:Prick into the seat seal (33) with a pointed object and pull it off the valve seat. Then remove the PTFE seal (34).

m. The lower shaft seal (33, 34) is removed from the housing as follows:Prick into the seat seal (33) with the metallic tip of the disassembly tool and pull it off to the top. Remove the PTFE seal (24) by means of the mandril of the assembly tool through the housing to the top.

n. Remove the seal ring (30) and the guide band (29) from the groove of the valve seat (6).



13

11.3 Actuator (Maintenance)

Attention: See to the seals and bearing surfaces of the seat lift cylinder and main cylinder being greased sufficiently!!! (also see lubrication chart RN 260.0064-1).

For the maintenance of the actuator (seat lift cylinder and main cylinder) the pneumatic air lines and proximity switches must be removed.

a. Seat lift cylinder

- Remove the complete valve insert from the housing.- Turn off stop sleeve (11) and screws (19).- Pull off the seat lift actuator (10) and the piston.- Seals (18, 22, 23, 25) and guide band (21) can be serviced.- Assembly in reverse order.

b. Main cylinder

- Lift the complete seat lift actuator (10).- Screw off the safety nut (16), remove the safety disc (17).- Lift the main cylinder (9).- Take off the piston (26) with cover (27) and pull the cover off.- Seals (22, 23, 25) can be serviced.- Assembly is done in reverse order.

11.4 Installation of product-wetted seals and assembly of the valve DELTA DA3

Attention: See to all seals and bearing surfaces in the product area being slightly greased before their installation(also see lubrication chart: RN 260.064-1).

a. Installation of the lower shaft seal (33, 34) in the lower housingflange (see page 16) .

b. Place the seal ring (30) and the guide band (29) in the groove of the valve seat (6).

c. Installation of the upper shaft seal (33, 34)Insert the PTFE ring (34), at first. Then press the elastomer ring (33), the wide side to the front, into the groove betweenPTFE seal and valve seat.

d. Press the upper and lower seat seal (36) into the seat ring (37).

Attention: The seal shoulder must fit properly into the groove (see ill. X)!!



seat ring 37

seat seal 36

groove

Ill.X

14


e. Insert the middle seat (38) into the lower shaft (3) by means of the assembly tool (see page 15) .Assembly without assembly tool:Press the slightly greased seal at four spots into the groove.Then press the four loops in by means of an even object. Vent the seal groove at this occasion.

f. Screw on the lower shaft (3). For this purpose, tighten the safetynut (42) to the metallic stop.

Tightening moment of safety nut (42) at lower valve shaft:Md = 40 Nm

g. Insert the upper and lower housing seal.

h. Place the O-ring (31) on the guide rod (4).

The further assembly of the valve is done in reverse order asdescribed in chapter 11.2.

11.5 Installation of the valve insert

a. Carefully place the valve insert in the valve housing until thescrew stops (see 11.1e).

b. Remove stop screw and carefully press the valve insert into thehousing.

c. Enter screws (7) and tighten them in crosswise manner.

d. Install the pneumatic air and cleaning lines.upper air connection A1 : lifting of lower areamedium air connection B : valve openlower air connection A2 : lifting of upper area.

e. Installation of valve position indication.Release nuts and push the proximitiy switches into the sleeve until they stop.

f. Fix the proximity switches by the nut.(Install CU if necessary.)

g. The spray connection (1) can be disassembled from the housing (2)by levering it by means of a wide screw driver (see sketch) .


15

12.1 Assembly tool for lower shaft seal, items 33, 34

For a simple disassembly and assembly of the lower shaft seala universal tool can be used. The use of this tool is especially recommended for valves of the small series (DN 40-65, 1,5T-3T),for the access to the lower shaft seal from the top being impossibleas a result of the narrow seat.

Attention:Do not damage the seal lip of the PTFE seal during assembly.To avoid injuries the disassembly tip must be covered by the assembly mandril if not used.

1) Assembly of the PTFE seal (fig. 1,2)

a) Press the PTFE ring into an oval shape.b) Insert the PTFE ring by means of the assembly tool from the top,

the wide side to the front, through the intermediate ring of thehousing into the lower housing (fig. 1) .

c) Pull the PTFE into a round shape by means of the assemblymandril (fig. 2/I) and press it into the groove - do not knock or beat (fig. 2/II).

2) Assembly of the elastomer seal (fig. 1,3,4)

a) Slightly grease the seal.b) Insert the elastomer by means of the assembly tool from the top, the

wide side to the front, through the intermediate ring of the housing into the lower housing (fig. 1) .

c) Fix the seal by means of the groove of the assembly mandril (fig. 3/I) .

d) Press in the elastomer at one spot between the housing flange and the PTFE (fig. 3/II) .

e) By sliding the assembly mandril around the seal, the seal is inserted completely into the groove (fig. 4) . See to an even fit of the elastomer seal in the groove.

12. Disassembly and Assembly Tool

2) 3)

1)

4)


disassembly tip

16

12. Disassembly and Assembly Tool

12.2 Assembly tool for middle seal

The assembly tool consists of:

(1) ring with vent nose

(2) thrust ring

(3) groove nut

(4) housing with two slewable brackets (7)

(5) union ring.

The assembly of the middle seal by means of the assembly tool is to be carried out as follows:

a. Remove the groove nut (3) and the ring (1) and the thrust ring (2).

b. Remove the union ring (5) from the assembly tool and push itover the lower shaft.

Attention: The bevel of the union ring and the lower shaft must lie upon another.

c. Insert the lower shaft with the union ring (5) into the housing (4) and fix them by the brackets.

d. Clamp the assembly tool by the brackets into the vice.

e. Insert the ring (1) into the housing in such a manner that the ventis within the seal groove of the lower shaft.

f. Slightly grease the middle seal (6) and place it around the ring (1).(installation position see ill.)

g. Insert the thrust ring (2).

h. Screw on the groove nut and tighten it by means of a wrench until it stops.

i. Release the groove nut. Pull ring and thrust ring out of the housing.

j. Take housing out of the vice, open the slewable brackets, take the shaft out of the housing and remove the union ring.Check the correct fit of the middle seal.


middle seal

lowervalve shaft

17

13. Detection of Seal Damage

The dismantling and installation of seals is done according to the assembly instructions.

The item numbers refer to the spare parts list drawingsDIN - RN 01.053.72; Tube - RN 01.053.73-1

SH5 - RN 01.053.73-2

* Leakage at the upper housing flange:replace housing seal (32).

* Leakage from the leakage boring between the connecting ports:replace lower housing seal (32) and lower seat seals (36).

* Leakage from the boring of the spring cylinder (8):replace upper shaft seal (33, 34) and seal in flushing chamber (30).

* Liquids from the drain pipe

- To be able to make a detailed diagnosis, remove the drain pipe (1).

a. Valve posi tion closed

- Pressure in upper housing

* Leakage at the inner side of the lower valve shaft (3).replace upper seat seal (36).

* Leakage at the inner tube of the lower valve shaft (3):replace upper shaft seal (33, 34).

- Pressure in lower housing

* Leakage at the inner side of the lower valve shaft (3):replace lower seat seal (36).

* Leakage at the outer side of the lower valve shaft (3):replace lower shaft seal (33, 34).

b. Valve posi tion open

* Leakage at the inner side of the lower shaft (3):replace middle seal (38).

14. Spare Parts Lists and Lubrication Chart

(see annex)


double seat valve delta da3 - alliance fluid handling

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