Instruction Manual
Contents
1. E 800 648 3326 EE oma E www omdean com oliver m dean inc 5308 5309 Ball Valve Tri Clover Ball Valve UltraPure Instruction Manual ESE01663 EN3 2010 12 Original manual Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice Ne SNV oer ic oaeccnad sooeseeciie a eee muse euee suena ene uadaeteeceseeemorecceaead Met Ab MOF Wed Ue UNO Meletal UII graeia E EE E R E Woe ct tie emo laze WVarMINGCIONG aesir veda ndoeeintaeede ted saddenneus sedenmatad somes aoaaa kos POETS PKCCAUNOMS irria a inet oieex Guten vied RE Aw Sk Mae Lowe INES ademas 2 Mantenan sevcecesdneisdcweridasdattadeDvibeiuweeibadubeaiwibalucceenbalndeadewentduniocincnedawesies Zoe VEIVGISESSCIMDIN vnpceincecmnes rin tharennens ioc EOT ETOO EE tee E ERES E E Zi NAN ENMISOCCHOM optrin nes eee ee oie a cated etc a more neh coon emate E ate eet ene Zos VINGAS SOMOV erreira uae enue ede onic geese eine ea EEEN ET 2 4 Attaching the actuator and Switch to the valve oo c cece ccc e eee e eee e ee eeeeeeeeeeneenes 3 IFECMMICALOaley tavetacccreus re acsena aa a a ecsacu tee Sle Torguevs Pressure Diferentidl evccchoninuees tance neasemanntenuctes men Dine sn TEEDELE SRi 4 Parts list and Service KitS anannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 4 1 Ball Valves UltraPure for 1 2 to 2 pieces ere tee cha atte eae tent aie tact tela Acti 4 2 Bal2. 9613830049 9613830045 9613830057 O Service kits Reinforced cece eee ees 9613830050 96138380062 9613830046 9613830042 9613830054 O Service kits Reinforced Encapsulated 9613830051 9613830063 9613830047 9613830043 9613830055 17 18 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 4 4 Ball Valve 5308 Series for 3 to 4 Ball Valves 5308 Series for 3 and 4 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided Parts list Pos Qty Denomination 8 a 2 Seat PTFE 10 o 1 V ring packing PTFE set 11 o 1 Stem seal PTFE 13 oO 2 Body gasket PFTE Service kits Denomination 3 4 Service Kits for 3 and 4 O Service kits Standard iicuiss nina eheek doe des endo his eevee es 9613830060 9613830068 O Service kits Standard Encapsulated cece eee ees 9613830061 9613830069 O Service kits REINfOrced prerio cece cece rE TEUER 9613830058 9613830066 O Service kits Reinforced Encapsulated cece eee eens 9613830059 9613830067 19 How to contact Alfa Laval Contact details for all countries are continually updated on our website Please visit www alf
3. slide the stem into the stem hole in the upper body of the valve 2 Press the upper packing rings 10 onto the stem 4 until it is seated against the base of the body 3 Press the packing retainer 9 onto the stem 4 until it is seated against the upper packing ring 10 4 Turn the stem 4 until the flat surfaces are parallel to the port centerline 5 Place a ball seat 8 inside one end of the valve body 1 so that the tapered side of the seat faces inward and the other side lies flush against the outer surface of the valve body 6 Seat the ball 3 inside the valve so that the stem base is seated inside the bore of the ball 3 7 Turn the stem 90 so that the valve is in the open position This keeps the ball from falling out of the valve 8 Place the other ball seat 8 inside the end of the valve body 1 so that the tapered side of the seat faces inward and the other side lies flush against the outer surface of the valve body 1 3 and 4 2 Maintenance All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 9 Assemble the valve body ends 2 with gaskets 13 in place to each end of the valve body 1 1 2 through 2 size use 4 bolts 14 and 4 bolt nuts 17 3 and 4 size use 4 studs 14 and 8 stud nuts 17 Refer to Table 1 for proper torques 10 Place spring washe
4. alaval com to access the information direct Alfa Laval Corporate AB This 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 this document 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 any form 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 AB will enforce its rights related to this document to the fullest extent of the law including the seeking of criminal prosecution
5. d 3 1 Torque vs Pressure Differential As the amount of pressure in a ball valve increases so does the amount of torque required to open and close it Use the charts below to determine the type of actuator if any that is required for your application PTFE Seat Material Ya 12 7mm 2 50 8mm Tube OD Nm in lb 27 240 24 5 216 22 192 19 168 F136 120 11 96 s m 54 48 ie ve somm 3 24 na 100 200 300 400 Line Pressure Reinforced PTFE Seat Material Yo 12 7mm 2 50 8mm Tube OD Nm lb in 27 240 24 5 216 ann 22 192 g 19 168 f oon 4 ave 16 144 13 6 120 m 8 72 yo 12 7mm 3 3 19 0mm 5 4 48 3 24 O O psig O 100 200 300 400 550 bar O 7 14 21 27 6 38 Line Pressure 10 Nm 163 136 108 5 Torque 81 4 54 27 Nm 190 163 136 Torque 108 5 81 4 54 in lb 1440 1200 960 720 480 240 Ib in 1680 1440 1200 960 720 480 psig bar 3 76 2mm 4 101 6mm Tube OD 0 100 200 300 Line Pressure 400 3 76 2mm 4 101 6mm Tube OD 0 100 200 300 O 7 14 21 Line Pressure 400 550 27 6 38 3 Technical data All warnings in the manual are summarized on this page Pay special att
6. ention to the instructions below so that severe personal injury and or damage to the valve are avoided 12 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 4 1 Ball Valves UltraPure for 1 2 to 2 Ball Valves UltraPure for 1 2 to 2 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided Parts list Pos Qty Denomination 8 Oo 2 Seat PTFE 10 a 2 Stem packing PTFE 11 o 1 Stem seal PTFE 13 oO 2 Joint gasket PTFE Service kits Denomination Yo 34 1 1 2 Service Kits for 1 2 to 2 o Service kits ASME cece cece eee ee eee 9614051102 9614051103 9614051104 9614051105 9614051106 O Service kits ISO DIN wo cece eee 9614051207 9614051208 9614051209 13 14 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 4 2 Ball Valves UltraPure for 2 1 2 to 4 Ball Valves UltraPure for 2 1 2 to 4 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay
7. l Vales UltraP re for 2 1 2110 4 espicn tenes recedeeeandet rr E EER ETLE rues 4 3 Ball Valve 5308 Series for 1 2 10 2 usannnnnunnnnnnnnrnrnnnenrnnrnenrrrrenrrrrnrrrrrrerrrrr 4 4 Ball Valve 5308 Series for 3 tOo 4 ruuuaannnnnnnrrnnnnrrrnnnerrrnrnerrrrrerrnrrnrrrrrrerrrrr 1 Safety Unsafe practices and other important information are emphasized in this manual Warnings are emphasized by means of special signs 1 1 Important information Always read the manual before using the valve WARNING Indicates that special procedures must be followed to avoid severe personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the valve NOTE Indicates important information to simplify or clarify procedures 1 2 Warning signs General warning Caustic agents gt gt 1 Safety All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 1 3 Safety precautions Installation Always read the technical data thoroughly Always release compressed air after use Operation Always read the technical data thoroughly Never touch the valve or the pipelines when processing hot liquids or when sterilizing Always handle lye and acid with great care gt be BPE Maintenance Always read the technical data thoroughly Always release com
8. lowing the ball to fall free from the valve 8 Press downward on the stem 4 until it presses through the inside of the valve body 1 and remove the stem and bottom stem seal 11 and the stem packings 10 9 Remove the joint gasket 5 from valve body ends You will need to use a small instrument such as a dental pick or small screw driver to pry the o ring away from the body end Be careful not to mar the body end in the process 2 2 Valve Inspection Seat s 1 Carefully examine the PTFE valve ball seats for cracking checking or excessive wear Leakage past the seat s may result from these types of irregularities Surface Finish 2 Inspect the bore of the ball and the valve stem in the valve upper body for signs of galling Replace both if galling exists Galling will continue to occur if only one part is replaced and the other is damaged Inspect the inside surface of each body end for marring Replace the end if damaged Leakage may occur from this kind of damage Gaskets O ring s 3 Inspect for cracks cuts abrasions flat spots or other damage that would cause leakage or ineffective cleaning Replace as necessary 2 Maintenance All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 2 3 Valve Assembly To assemble a ball valve 1 Place the lower packing ring 11 on the valve stem 4 and
9. pressed air after use Never service the valve when it is hot Never service the valve with valve and pipelines under pressure Never stick your fingers through the valve ports if the actuator is supplied with compressed air gt gt pD 2 Maintenance All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 2 1 Valve Disassembly To disassemble a ball valve 1 For a manual valve remove the top handle nut 20 from the stem 4 2 Remove the handle 7 For actuated valves remove bracket mounting bolts and remove actuator bracket and coupler Note If you are disassembling a 3 or 4 inch valve you ll need to remove the actuator mounting bolts 3 To remove the second stem nut you must first bend back the side tab of the stop washer 12 This can be done using a screw driver or punch Once the stop washer side tab is flattened you can remove the stem nut 5 Note 3 and 4 inch valves will require a socket wrench to reach the nut recessed into the mounting bracket 36 mm 4 Remove bevel washers 6 and gland bushing 9 5 Remove four hex nuts 17 from one side of body bolts 14 For the 4 inch valve remove six hex nuts 17 Remove body bolts studs to allow bodyends 2 to fall away 6 Remove the front and rear ball seats 8 7 Turn the stem 4 clockwise until the ball 8 is in the closed position al
10. re personal injury and or damage to the valve are avoided 2 4 Attaching the actuator and switch to the valve Attaching the Switch to the Actuator 1 Remove the position indicator on the top of the actuator 1 2 Attach the bracket 10 to the top of the actuator using four bolts 11 a 3 Insert the switch stem through the center hole in the bracket 10 and align with the slot in the actuator shaft 4 Attach the top of the bracket 10 to the switch using four bolts 9 Attaching the Actuator to the Valve These instructions describe how to attach an assembled actuator to a Tri Clover Ball Valve For information on servicing your electric or pneumatic actuator refer to the service manual that comes with the actuator To attach the actuator to the valve 1 Remove handle nut and handle 2 Sizes through 2 attach actuator bracket to valve body using 4 bolts provided in kit 3 Place actuator coupler onto the valve stem 4 Place actuator on the mounting bracket on sizes 3 and 4 valves the bracket is included on all valves as part of the body Be sure to line up coupler with actuator Tighten all bolts 5 Instal 4 actuator mounting bolts through bracket and into the bot tom of the actuator Tighten all bolts 3 Technical data All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoide
11. rs 6 together so that their curved surfaces are facing outward in opposite directions and place them over the stem 4 11 Place stop washer 12 onto stem 4 Making sure the stop washer lock tab is flat Instal stem nut 5 onto valve stem 4 Refer to table 2 for stem nut tightening torque Once stem nut is properly tightened bend tab of lock washer 12 up against the stem nut 5 using a screwdriver or punch Instal handle 7 over valve stem 4 and secure with handle nut 20 Be sure the handle locking devise 18 will align with both locking notches in valve body 1 If you are using an electric or pneumatic valve place the actuator bracket assembly on the upper body of the valve and secure it to the valve with two mounting bracket screws 13 Bolting Torque Data for Sanitary Ball Valves Table 1 Valve For Body Bolting Size Size in lb NM Vo v4 20uNC 80 9 4 14 20unc 80 9 1 5 16 18unc 110 12 Zs 3 8 16unc 170 19 Ze 7 16 14unc 230 26 3 5 8 11uNnc 570 64 4 5 8 _ 11unc 600 68 Table 2 Valve For Stem Unit Size Size in NM ai 3 8 24unf 87 9 8 Sa 3 8 24unf 87 9 8 1 3 8 24unf 87 9 8 We 7 16 20unf az koe 2 9 16 18unf 165 18 6 3 M24 191 21 6 4 M24 191 21 6 2 Maintenance All warnings in the manual are summarized on this page Pay special attention to the instructions below so that seve
12. special attention to the instructions below so that severe personal injury and or damage to the valve are avoided Parts list Pos Qty Denomination 8 oO 2 Seat PTFE 10 o 1 V ring packing PTFE set 11 o 1 Stem seal PTFE 13 oO 2 Body gasket PFTE Service kits Denomination 2 1 2 3 4 Service Kits for 2 1 2 to 4 0 Semice kits ASME seusan ae a A O N OEA 9614051107 9614051108 9614051109 o0 Service kits ISO DIN woo ccc cece eee eee ee ee ee en eneees 9614051210 9614051211 9614051212 15 16 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided 4 3 Ball Valve 5308 Series for 1 2 to 2 Ball Valves 5308 Series for 1 2 to 2 4 Parts list and Service Kits All warnings in the manual are summarized on this page Pay special attention to the instructions below so that severe personal injury and or damage to the valve are avoided Parts list Pos Qty Denomination 8 Oo 2 Seat PTFE 10 o 2 Stem packing PTFE 11 o 1 Stem seal PTFE 13 oO 2 Joint gasket PTFE Service kits Denomination Yo 34 1 1 2 Service Kits for 1 2 to 2 o Service kits Standard ccccee ee ee eee 9613830052 9613830064 9613830048 9613830044 9613830056 O Service kits Standard Encapsulated 9613830053 96138380065
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