Double Seal Valve DELTA SD4 - Alliance Fluid Handling · 1. General Terms 2 Double Seal ValveDELTA SD4 Operating Manual Rev.0. Double seal valves DELTA SD4 have been developed for

Double Seal Valve

DELTA SD4

Operating Manual

Rev.0

BA SD4 0 000002Ident-No.: 176 061

APV Rosista GmbHZechenstrasse 49D-59425 UnnaTel. : (02303) 1 08 - 0Fax. : (02303) 1 08 - 210

1. General Terms

2. Safety Instructions

3. Mode of Operation

4. Auxiliary Equipment

5. Cleaning

6. Installation

6.1 Welding Instructions

7. Dimensions / Weights

8. Technical Data

9. Maintenance

10. Assembly Instructions

11. Trouble Shooting

12. Modification of Actuator

13. Spare Parts Lists

Double Seal ValvesSD4, SDE4

DN design RN 01.054.62Tube design RN 01.054.62-1

Actuator RN 01.054.86

Leakage valve RN 01.054.67

Table of Contents

1Double Seal ValveDELTA SD4Operating ManualRev.0

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

We have to point out that we will not accept any liability for damage or malfunctions resulting from the non-compliance with thisoperating manual.

Descriptions and data given herein are subject to technical changes.

2. Safety Instructions

DANGER!

- The technical safety symbol draws your attention to importantdirections for operating safety. You will find it wherever the activities described are bearing risks of personal injury.

- Electric and pneumatic connections must be separated.

- Before any maintenance of the valve, the line system must be depressurized.

- Do not reach into the open valve.

- Risk of injury by suddenly operating valve. In dismantled state there is the risk of bruising at movable parts of the valve.

- Observe assembly instructions to ensure safe maintenanceof the valve.

- Attention!With valve design NC (normally closed): Before releasing the housing screws, the valve insert must be relieved bycontrolling the actuator.

- The welded actuator is under spring load, do not open it by force.

1. General Terms


Double seal valves DELTA SD4 have been developed for the usein the brewing and beverage industries, in dairy and food applications as well as for the chemical and pharmaceuticalindustries.

The field of application of the DELTA SD4 comprises the safeshut-off of line sections which are separated from one another by two seat seals. A leakage chamber is arranged between the seals,the leakage chamber being forcible closed by the two leakage valves or opened to the atmosphere.

Leakage at the seat seals is discharged via the leakage valves to the atmosphere and indicated.

- Operation by pneumatic actuator with air connection.The actuator is generally mounted normally closed (NC).

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

- To avoid pressure hammers, the valve is to be closed against the flow direction of the fluid.

- As standard design a control unit DELTA CU21N with NOT element is installed on top of the actuator for the pneumatic control of the valve. The NOT element fulfills the task to increase the closingforces of the closed valve.

- The yellow luminous diodes in the control unit indicate the position of the valve shaft.

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

4. Auxiliary Equipment

- Valve position indicationA proximity switch holder for the valve position indication can beinstalled direct on the actuator.With SD4 valves being equipped with valve position indication it must be observed that the max. closing pressure is reduced compared with the valve design being equipped with the control unit DELTA CU21N.(see table, item 8)Proximity switches to signal the limit position of the valve seat can be installed at the proximity switch holder if requested.We recommend to use one of our APV standard types:operating distance: 5 mm / diameter: 11 mm.If the customer decides for a valve position indication other than APV type, we cannot take over any guarantee for a faultless function.

- Field busThe direct assembly of an intelligent control unit DELTA CU21VN,Valve-Net with NOT element (field bus technology) is also possible.

3. Mode of Operation

3Double Seal ValveDELTA SD4

Operating ManualRev.0

For the cleaning of SD4 valves one has to distinguish betweentwo areas.

- The flow chambersThe passages of the valve are cleaned by the cleaning liquidduring the cleaning of the connected pipelines.

- The leakage chamberThe cleaning of the leakage chamber is effected via the leakage valves. The cleaning liquid is supplied via one leakage valve and discharged to the atmosphere via the second leakage valve.

The restraint passage of the cleaning liquid provides for a perfect cleaning of the whole leakage chamber.

Under normal conditions, 15 valves DN 25/1T - 100/4T can becleaned by one spray distribution line DN 25.

Recommendation for cleaning times with usual operatingconditions and CIP liquids.

5. Cleaning


- Depending on the pressure ratio, cleaning temperatures and degree of soiling, different times have to be adjusted.

- Flushing quantity per CIP spraying about 1,2 ltr/10 s- Cleaning pressure at CIP cleaning connection min. 2 bar

max. 5 bar.

Cleaning of the leakage chambervia the leakage valves.

cleaning step CIP - spr ayingpre-flushi ng 3 x 10 sec.caust ic flushi ng 80o C 3 x 10 sec.interm ediate flushi ng 2 x 10 sec.acid flushi ng 3 x 10 sec.subsequent flushi ng 2 x 10 sec.

- Installation has to be done in such a way that fluids can drain off the valve housing and is preferably to be realized in vertical position.

- The valve housing can be welded direct into the pipeline(compl. dismantable valve insert).

- Attention : Observe welding instructions.

6.1 Welding Instructions

- Before welding of the valve, the valve insert must be dismantled from the housing. See to a careful handling to avoid damage tothe parts.

- 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 from the outside tothe 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 housings or of the mating flanges and after work at the pipelines, the corresponding parts of theinstallation or pipelines must be cleaned from welding residuesand 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.

6. Installation



7. Dimensions / Weights


dim ensions in m m

DN A B ˘̆ D F H L 1 L 2 Est roke

inm m

˘̆ Kw eightin KgSD4

w eightin KgSDE4

25 397 14,5 26 50 60 447 471,5 200 15 86 5,4 5,840 403 20,5 38 67 72 470 495,5 200 25 86 6,1 6,650 440 26,5 50 72 84 512 550,5 200 28 126 8,3 8,865 448 35,0 66 85 100 533 583,0 200 28 126 10,0 10,580 501 42,5 81 98 115 599 658,5 200 28 189 16,5 17,1

100 511 52,0 100 111 134 622 697,0 200 28 189 18,3 18,9

Tube1T 395 12,5 22,6 50 56,6 445 464,1 200 15 86 5,4 5,8

1,5T 401 19,0 34,9 67 68,9 468 488,9 200 25 86 6,1 6,62T 439 25,4 47,6 72 81,6 511 546,0 200 28 126 8,3 8,8

2,5T 445 31,8 60,3 85 94,3 530 571,1 200 28 126 9,5 10,03T 496 38,0 72,9 90 106,9 586 640,9 200 28 189 15,6 16,24T 509 50,8 97,6 111 135,6 620 695,5 200 28 189 18,3 18,9

SD 4 SDE 4

Product-wetted parts: 316 L, 1.4404

Other parts: 1.4301

Seals: standard: EPDMOptions: Silicone, Viton, HNBR

Actuators: 1.4301

Max. operating temperature: 140 oC EPDM135oC Silicone, Viton

Sterilization temperature: up to 150 oC EPDM(short-term) 140 oC Silicone, Viton

Air connection (for hose): 6 x 1 mm

Max. pneumatic air pressure: 8 barMin. pneumatic air pressure: 6 bar

(Use dry and clean pneumatic air, only.)

Closing times for double seal valves SD4The opening and closing times can be fixed by adjustment of thethrottling screw at the solenoid valve.

8. Technical Data

7

kvs val ues for SD4val ves in (m 3 / h)

SD41, SD42SDE 43, 44

SD41, SD42SDE 43, 44

DN25 19 2040 42 3950 88 7065 145 12080 175 190

100 220 265

Tube1T 15 16

1.5T 39 262T 79 63

2.5T 124 1063T 155 1504T 215 258

Double Seal ValveDELTA SD4Operating Manual

Rev.0

9. Maintenance

- The maintenance intervals depend on the corresponding application and are to be determined by the operator himself carrying out temporary checks.

- Required tools:

- 1 x spanner SW13- 1 x spanner SW17- 1 x spanner SW19- 1 x hexagon socket screw key 6 mm

- Exchange of seals is done according to assembly instructions.

- Slightly grease all seals before their installation .

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

! No matter what type of application, use only those greases being suited for the respective seal mater ial !

8. Technical Data

8

DELTA SD4 m ax. product pressures in (bval ve norm al ly cl osed and w ith NO T elem

˘̆ 74 m mact uat or



DN Tube25 1T 16,0 16,840 1,5T 12,4 17,650 2T 17,6 17,6

2,5T 14,0 16,065

3T 17,680

100 4T 12,8

m ax. product pressure lim ited to 17,6 baby seal technol ogy

DELTA SD4 m ax. product pressures in (bval ve norm al ly cl osed w ithout NO T elem

- w ith com pressed ai r fai lure




DN Tube25 1T 6,4 16,040 1,5T 3,6 9,650 2T 6,0 11,2

2,5T 4,7 11,665

3T 8,080

100 4T 4,4

Double Seal ValveDELTA SD4Operating ManualRev.0

DELTA SD41, SD42, SDE43, SDE44The item numbers refer to the corresponding spare parts listsDN: RN 01.054.62 / Tube: RN 01.054.062-1.

I. Dismantling from the line system

a. Shut off line pressure and discharge lines if possible.

b. Control actuator with air.

Do not reach for movable parts!Risk of injury.

c. Remove housing flange screws (4) and lift insert off the housing (1).

d. Shut off compressed air and detach air supply.

The actuator is loaded with compressed air, via theNOT - Element.

e. Detach control unit (22) from actuator (18).(Turn ring in anticlockwise direction.)

II. Dismantling of wear parts (product-wetted parts)

a. Remove housing seal (3).(installation see 9.V.e)

b. Screw off actuator screw in the control unit.

c. Release hex. nut (21), while holding up the centering washer (20).Detach centering washer.

d. Pull valve shaft (2) off the actuator (18), remove seat seals (12, 11).(installation see 9.V.c.,d.)

e. Screw off yoke (5) from actuator (18).

f. Remove seat seal (10), shaft seal (9) and guide bush (8).(installation see 9.V.a.)

III. Actuator

Actuator: RN 01.054.86

g. Remove air hoses from actuator.

h. Release inner hex. screws from the adapter of the control unit.

i. Release the two seal screws (1), while holding up the actuator by means of a strap wrench. Remove O-rings (3) as well as seals (2).




IV. Installation of seals and assembly of the actuator

a. Install the slightly greased O-ring (3) and the seal (2) in theseal screw.See to the correct direction of installation of the seal.

b. Push seal screws over the piston shaft at both sides of the actuatorand tighten them.

c. Fasten the adapter for the control unit and the yoke at the actuator.Attention: Observe the position of the adapter.

d. Install air hoses.

V. Installation of seals and assembly of valveThe item numbers refer to the corresponding spare parts listsDN : RN 01.054.805 / Tube : RN 01.054.806

a. Place the guide bush (8) in the yoke (5).Then insert the shaft seal (9) and press in the slightly greasedseat seal (10).See to the correct direction of installation.

b. Install yoke (5) on actuator (18).

c. Insert the two seat seals (11, 12) into the shaft.Slightly grease seat seals before their installation.During the installation in the seal groove, the seal groove is to bevented between the seal ring and the groove wall by means of athin object. See to a correct fit of the seals.

d. Push shaft (2) through yoke (5) and actuator (18), place the centering washer (20) and tighten the nut (21) until it flushes with the top. Hold up the centering washer. Tightening moment 40 Nm.Tighten actuator screw.

e. Slightly grease housing seal (3) and insert it into the groove of theyoke flange.



VI. Assembly of the valve

a. Place the control unit (22) on the adapter (19) and secure itby the fastening ring.

b. Connect air supply and control actuator (18) with air.

Do not reach for movable parts!Risk of injury.

c. Carefully place the valve insert in the housing (1) and tighten thehex. screws (4). Ths housing seal (3) must not be damaged during this procedure.

d. Shut off compressed air.

e. Check basic adjustment of the valve position indication.

- By turning the positioning screw in the control unit the shift points can be adjusted.

VII. Maintenance of the leakage valves

The item numbers refer to the spare parts listsleakage valves: RN 01.054.67.

a. Pull off pneumatic air hoses at the two leakage valves.

b. Shut off CIP supply line and discharge it.

c. Remove CIP supply and outlet line from the leakage valves.

d. Release inner hex. screw and remove bracket.

e. Turn off cover (3) and pull off piston (2) and spring (6).

f. Dismantle all seals (5, 7, 8).

g. Installation is done in reverse order.


11

leakage valve

Double Seal ValveDELTA SD4Operating Manual

Rev.0

The item numbers refer to the respective spare parts drawings.

- Valve is untight,leakages via theleakage valves : Replace seat seals (11, 12).

Check line pressure:perm. line pressure see 8 .

- Leakages at the cylinderof the leakage valve : Replace O-rings (5, 7, 8).

Check cleaning liquid supply.

- Leakages betweenhousing andyoke flange : Replace housing seal (3).

- Shaft passage in theyoke is untight : Replace shaft seal (9, 10).

- Air escapes from theactuator : Dismantle actuator (18) from(see spare parts list valve, replace seal (2) andRN 01.054.86) O-ring (3) in the seal screw (1).

- Actuator does not work,air escapes permanently via the venting plug : Replace actuator.

- Valve position indicationis missing or unprecise : Carry out fine adjustment

according to assembly instructionsof control unit.

11. Trouble Shooting


With SD4 valve, the size of the actuator can be changed.

To increase or decrease the actuator sizes (Ø 74 mm, Ø 110 mm, Ø 165 mm), the corresponding line pressures must be considered, see table page 8.

I. Modification of actuatorDismantling

a. The dismantling of the double seal valves is done as describedin 10, items I. and II.

b. To change the actuator size, the guide rod (6) must be replacedas follows:Fix the valve seat in a vice.

Attention: See to the valve seat not being damaged(use protective jaws or cleaning rags).The slightest damage at the shaft rod can lead to leakages.

c. The guide rod can be turned out of the shaft by means of the centering washer (20) and a spanner SW17.

Assembly

a. Turn the corresponding guide rod into the shaft to the actuator.Tightening moment: 40 Nm

b. Further assembly as described in 10, items IV. to VI.

13. Spare Parts

(see annex)

12. Modification of Actuator



Double Seal Valve DELTA SD4 - Alliance Fluid Handling · 1. General Terms 2 Double Seal ValveDELTA SD4 Operating Manual Rev.0. Double seal valves DELTA SD4 have been developed for

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