Operating Manual Cleaning Air/Valve Combination RLV Unit

Operating Manual Cleaning Air/Valve Combination

RLV Unit (Type 09708, 09709, 09712, 09713)

BA 009700.04 EN

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713

BA_009700.04_EN Albert Handtmann Armaturenfabrik GmbH & Co. KG 2016-10-14 2 / 15

Overview Page Page

Table of Contents 2

1. General 3 Operating Instructions 6 Proper Application 3 Design Variants 7

Incorrect Application 3 Technical Data 7 The User's Duty to Exercise Diligence 3 5. Disassembly and Assembly 8

2. Safety Information 4 Safety and Assembly Instructions 8

Symbols 4 Single Assemblies, Spare Parts 9 Safety Instructions 4 6. Maintenance 14

3. Delivery and Performance, Storage 5 Maintenance Instructions 14

4. Function and Operation 6 Troubleshooting 15 System Description 6 Spare Parts 15

Safekeeping and Completeness

• The operating manual is part of the delivery package and must be available to authorised personnel at all times.

• It is impermissible to delete chapters from this manual. If the operating manual or pages thereof are missing, they must be replaced immediately.

Updating Service

This documentation is not subject to the updating service of Albert Handtmann Armaturenfabrik GmbH & Co. KG. Amendments to this document may be carried out without prior notification.

Copyright

This documentation contains copyrighted information. It should only be used in connection with the use of the RLV unit.

Manufacturer

Albert Handtmann Armaturenfabrik GmbH & Co. KG Arthur-Handtmann-Str. 11; 88400 Biberach, Germany Tel.: +49(0) 73 51/3 42-0; Fax: +49(0) 73 51/ 3 42-44 80 E-mail: [email protected]

Operating manual edition

C 08/2015

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


1. General This operating manual must be read and observed by everyone involved with the installation, the commissioning, the operation, the assembly or the maintenance of the RLV unit.

This operating manual applies to the following versions:

Types RLV with safety armatures 09708 Spring-loaded vacuum valve

09709 ------

09712 Spring-loaded safety valve, spring-loaded vacuum valve

09713 Spring-loaded safety valve, weight-loaded vacuum valve

Proper Application

• RLV units are used in the food and beverages industry.

• The RLV unit is installed on a process tank or manhole cover and fulfils tasks in CO2/gas distribution and the CIP cleaning of the tank interior.

• The safety armatures on the RLV unit are used to provide overpressure and underpressure protection in closed process tanks.

• RLV units may be used for the intended purpose only. Always pay attention to country-specific guidelines, tank design, installation situation and specified process data, such as media, pressure and temperature.

Foreseeable Misuse

The following are examples of misuse:

• Generally recognised safety guidelines are not observed during installation, operation, assembly and maintenance.

• The application of operating conditions and media that deviate from those specified in the operating manual. • Unauthorised modifications or changes to the RLV unit that impair its safety or functionality.

• The RLV unit and the installed safety armatures are used although they are not functional.

The User's Duty to Exercise Diligence

The user must especially ensure that:

• The installation and the media connections are correct and safe. • It is operated according to its intended purpose and in a fully functional state. • The statutory requirements for commissioning, operation, assembly and maintenance are observed. • Only sufficiently qualified and authorised personnel carry out the necessary tasks.

• The safety and warning instructions on the device are not removed and remain legible.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


2. Safety Information

2.1 Symbols

Risk of injuries!

Indicates an immediate hazardous situation!

• Non-observance may result in serious injury or death.

Caution – danger zone warning!

Indicates a potentially hazardous situation!

• Non-observance may result in minor to moderate injury

Functional impairment or material damage! Indicates a possible functional impairment or material damage:

Note Important additional information, tips and recommendations.

2.2 Safety Instructions

Note The following safety information must be considered as an addition to the relevant applicable national accident prevention requirements and laws. Current standards of good engineering practice must be observed when planning the application and operation of the device. Please pay attention to the relevant rules and safety regulations in other countries.

Basic safety instructions to prevent injuries and to ensure correct functioning:

• Transportation and storage are carried out correctly in accordance with the operating manual.

• Installation and maintenance tasks as well as operating actions should only be carried out by appropriately authorised and qualified personnel with suitable tools.

• The device should only be installed and operated when in efficient working order and in accordance with the operating manual.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


Risk of injuries!

• The RLV unit is sometimes installed at a high point on the process tanks.

• Risk of injury due to the RLV unit falling or uncontrolled unit movements during transportation and lifting.

• If the RLV units are used outdoors, heating elements can be fitted.

• Performing work on the RLV unit or operating armatures manually when the pressure in the process tank has not been released, or the piping system has not been shut off, may result in burns, scalding or chemical burns.

• If the RLV unit is operated in a system with acidic or alkaline media, your hands and fingers may suffer chemical burns when disassembling the unit.

• If the RLV unit is operated in a system with hot media, a high surface temperature may occur.

• There is a risk of crushing due to moving parts.

o Secure access and safe work at height must be guaranteed.

o Never pass under suspended loads and avoid the swivel range.

o Ensure that they are switched off electrically during maintenance work.

o Ensure that the piping system is shut off and the pressure inside the tank has been released.

o Ensure that the product area of the system is rinsed in advance.

o Make sure that the system has cooled to a value below 50°C.

o Never reach into the switching section of the armatures.

3. Delivery and Performance, Storage

• Check the information on the delivery note for correctness and check the delivery for completeness. Later complaints will not be accepted.

• Conduct a visual inspection for transport damage. The forwarding agent must be informed of any visible damages immediately (comment on the waybill).

• Claims due to transport damage not visible right away must be made to the forwarding agent within a week.

• Store the delivery in dry rooms and, if possible, in the original packaging to protect it against external factors.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


4. Function and Operation

4.1 System Description RLV units are used in hygienic processes. Only one central connection is required for the installation on the upper tank floor. This is why it is called a "1-hole RLV". The media are supplied via a combined CIP/gas standpipe on the process tank. The RLV unit with the integrated switching valve takes on the functional separation between the CIP tank cleaning and the CO2 supply and outflow.

• The spring-loaded switching valve is normally opened. • During the gas supply of air/CO2, this can flow into the process tank (purging, pretensioning)

or the CO2 which collects during the fermentation can flow out of the process tank.

• During the supply of CIP liquid, the switching valve is closed by the flow pressure. • The CIP liquid is guided into the process tank via the spray head. A small quantity of liquid flows around the

switching valve and cleans the rear valve seat area.

4.2 Operating Instructions

Note Correct and safe operation of the RLV unit is only guaranteed if the descriptions and instructions in the operating manuals for the safety armatures and spray head are also observed.

• Overpressure and underpressure protection of the process tank with installed safety armatures, especially safety and vacuum valve. (Observe setting pressures!)

• Internal cleaning of process tank with a static or dynamic spray head. (Liquid pressure of 1.5 to 2 bar must be observed!)

• Controlled, uniform gas supply. (Flow velocity max. 30 m/s, avoid high pressure change)

The product-side cleaning of the RLV unit and the safety armatures is performed during the tank cleaning by means of corresponding cleaning holes in the spray head pipe. The RLV unit must be aligned in such a way that the cleaning holes are aligned with the respective armature.

Installation of the RLV unit must ensure that soiling caused by ambient conditions is either fully excluded or minimised. The outer surface of the manhole cover unit should be cleaned by hand at regular intervals.

Risk of injuries!

See Chapter 2.2

Note Only use cleaning agents which are appropriate for stainless steel and the seals. Please refer to the safety data sheets of the cleaning agents.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


4.3 Design Variants *)

009708 / 009709

• 1-hole RLV unit, consisting of a switching valve for CIP/CO2 distribution and with/without vacuum valve

>> Applications in simple processes

>> Applications in smaller tank volumes

009712

• 1-hole RLV unit, consisting of a switching valve for CIP/CO2 distribution and with safety valve and vacuum valve

• Spring-loaded safety valve (acc. DGRL/PED or ASME UV)

• Spring-loaded vacuum valve

>> Application for standard CIP processes >> Applications in smaller and medium tank volumes

009713

• 1-hole RLV unit, consisting of a switching valve for CIP/CO2 distribution and with safety valve and vacuum valve

• Spring-loaded safety valve (acc. DGRL/PED or ASME UV)

• Weight-loaded vacuum valve

>> Application for standard CIP processes >> Applications in large tank volumes

*) Other customer-specific variants are possible

4.4 Technical Data

Product range Operating data Materials Stainless steel 1.4301, 1.4307 Operating pressure Up to 10 bar

Surface Ra ≤ 0.8 µm Temperature CIP / SIP 0 - 95°C

Seals EPDM

Production / CIP Process media Liquids and gases, (non toxic, less aggressive) CIP media Commercially available alkaline and acidic solutions, concentration range 2-3%.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


5. Assembly and Disassembly

5.1 Safety and Assembly Instructions

Risk of injuries!

See Chapter 2.2

Caution – danger zone warning!

Please pay attention to the following prior to installing and commissioning the RLV unit: • Check the unit for visible external and internal damage. • Check the current system status (pressure, temperature, medium). • Pay attention to the safety instructions and the instructions regarding the assembly,

operation and maintenance of the RLV unit and safety armatures in the respective operating manuals.

Caution – functional impairment or material damage!

Installation instructions: • The RLV unit should be installed free of tension – for larger units a suitable, safe

hoisting device can be used. • Clean the joining surfaces in advance and ensure the seal is positioned correctly. • Welding work (TIG, welding gas) should only be carried out by qualified welders

(EN 287-1). • Always remove weld residue.


Assembly instructions: • Do not damage the valve insert, sliding surfaces or sealing surfaces.

Only use suitable tools and tensioning devices. • Only use suitable and approved spare parts from the manufacturer. • Slightly grease seals and insert them evenly into the groove.

(Only use grease approved for the field of food processing) • Bolts, slightly grease threads. Tighten parts evenly. • Following assembly work, you should always perform a function check.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


5.2 Single Assemblies 5.2.1 RLV Type 09708 RLV Type 09709 (Combination with vacuum valve) (without vacuum valve)

Spare parts:

Position 11 Position 14

Switching valve (spray head pipe)

Sealing ring with collar Sealing ring (DIN 11851)

DN DN Art. no. DN Art. no. 25 65 105054 25 103344 32 80 105055 32 103345 50 100 105056 40 103346 50 103347

Seals: Material EPDM Exchanging spare parts: The switching valve is wear-free and can be dismantled easily if necessary:

• Remove RLV housing > Pull the spray head pipe (6) upwards out of the tank connection (8), removing the spray head in advance if necessary > Replace the seal (11)

1 RLV housing

2 Switching valve

4 Vacuum valve

5 CIP connection

6 Spray head pipe

8 Tank connection

9 Pressure spring

10 Split-pin

11 Sealing ring with collar

14 Sealing ring (CIP)

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


• Dismantle switching valve > Remove the split-pin (10) from the spray head pipe (6) > Remove switching housing (2) > Replace the pressure spring (9)

5.2.2 RLV Type 09712 (Combination with vacuum valve and safety valve, both spring-loaded)

RLV Process tank Connections SK SV VV [DN 1] to ∅ [m] Tank [DN 1] CIP [DN 3] [DN 2] [DN] [DN]

65 3.0 65 40 25 25 - 40 40 - 50 80 3.0 80 50 25 40 - 65

50 - 65

4.5 50 32 100 3.0 100 65 25 50 - 80

65 -80

4.5 65 32 6.0 65 50

Vacuum valve VV 012501, 012537

Tank connection [DN 1] DN 65-100 (disc/grooved nut) DN 80-100 (flange 11301)

Spray head SK [DN 2] 009515

Safety valve SV (DGRL/PED) 032504, 032604 033501, 033601 Safety relief valve SV (ASME UV) 033551, 033651

CIP connection [DN 3]

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


Spare parts:

Position 11 Position 12 - 14 Position 15


Sealing ring with collar Sealing ring (DIN 11851) Sealing ring (DIN 11851)

DN DN Art. № DN Art.№ DN Art. № 25 65 105054 25 103344 65 103348 32 80 105055 32 103345 80 103349 50 100 105056 40 103346 100 103350 50 103347 65 103348 80 103349 100 103350

Exchanging spare parts:

The switching valve is wear-free and can be dismantled easily if necessary:

1 RLV housing

2 Switching valve

3 Safety valve (SV)

4 Vacuum valve (VV)

5 CIP connection

6 Spray head pipe

7 Spray head

8 Tank connection

9 Pressure spring

10 Split-pin


12 Sealing ring (SV)

13 Sealing ring (VV)

14 Sealing ring

15 Sealing ring

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


• Remove RLV housing > Pull the spray head pipe (6) upwards out of the tank connection (8), removing the spray head in advance if necessary > Replace the seal (11)


5.2.3 RLV Type 09713 (Combination with weight-loaded vacuum valve and spring-loaded safety valve)

RLV Process tank Connections [DN] SK SV VV [DN 1] to ∅ [m] Tank [DN 1] CIP [DN 3] [DN 2] [DN] [DN]

80 3.0 80 65 25 25 - 40 80

4.5 80 32

100 3.0 100 65 25 40 - 50 100

4.5 80 32

150 3.0 150 65 25 40 - 65 150

4.5 80 32

6.0 ; 10.0 100 50 ; 65

200 3.0 200 65 25 50 - 80 200

4.5 80 32

6.0 ; 10.0 100 50 ; 65

Vacuum valve VV 012504

Tank connection [DN 1] DN 80 - 100 (disc/grooved nut) DN 80 - 200 (flange 11301)

Spray head SK [DN 2] 009515, 009516

Safety valve SV (DGRL/PED) 032504, 032604 033501, 033601 Safety relief valve SV (ASME UV) 033551, 033651

CIP connection [DN 3]

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


Spare parts:

Position 11 Position 12 - 14


Sealing ring with collar Sealing ring (DIN 11851)

DN DN Art. № DN Art. № 25 65 105054 25 103344 32 80 105055 32 103345 50 100 105056 40 103346 50 103347 65 103348 80 103349 100 103350

Seals: Material EPDM

1 RLV housing

2 Switching valve

3 Safety valve (SV)

4 Vacuum valve (VV)

5 CIP connection

6 Spray head pipe

7 Spray head

8 Tank connection

9 Pressure spring

10 Split-pin


12 Sealing ring (SV)

14 Sealing ring (CIP)

15 Sealing ring (tank)

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


Position 15

Vacuum valve

DIN screw connections Sealing ring (DIN 11851)

Flange connection Sealing ring / O-ring

DN DN Art. № DN Art. № 80 80 103349 80 103349 100 100 103350 100 103350 150 --- --- 150 103489 200 --- --- 200 100050

Exchanging spare parts: The switching valve is wear-free and can be dismantled easily if necessary:

• Unscrew the CIP connection (5) > Screw connection directly on RLV housing, switching valve (2) is exposed > Remove spray head pipe (6) gently from the housing supports so that the seal (11) is accessible > Replace seal (11) (pull over spray head pipe)


6. Servicing

6.1 Maintenance Instructions


Inspection and maintenance intervals:

• Visual inspection of the RLV unit must be carried out every 4 weeks. >> Check for leaks, perform a manual function test

• To ensure that the RLV unit and installed armatures are ready for operation and functionally reliable, they should be checked annually within the scope of the general internal maintenance procedure.

>> Maintenance intervals must be set by the user • After maintenance, always remove protective devices and reconnect the feed and

drain lines to the RLV unit. • Ensure that a function check is always performed following maintenance work,

including for the safety armatures.

Operating Manual

RLV Unit

09708 / 09709 / 09712 / 09713


6.2 Troubleshooting

Faults Possible causes Measures

RLV unit leakage

• Seal between the flange and the housing damage

• Flange bolts have become loose

• Screw connections at the installed components have become loose

• Replace seal • Test tightening torque

Retighten screw connections

Noise development • Uneven flow

• Check process conditions

Throughput fluctuation • Poor CIP cleaning

• Poor gas supply and outflow

• Check CIP supply • Check spray head • Check switching valve

• Check piping system • Check switching valve • Check gas throughput and

gas pressure

Malfunctioning safety armatures

• See operating manual for respective armature

• Faults must be eliminated immediately

6.3 Spare Parts

Note Spare parts for the safety armatures should be taken from the respective operating manual of the armature.

Documents

Operating Manual Cleaning Air/Valve Combination RLV Unit