The document provides operating instructions for the DELTA DA3+ double seat valve. It describes the valve's mode of operation as separating two pipelines using two independently operating valve slides. It also details safety instructions, cleaning procedures, installation requirements, technical specifications, and maintenance instructions.
1. DELTA DA3+
Double Seat Valve
Improving Process Profitability...Continuously
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Operating Manual
APV Products
invensys
2.
3. 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. Service 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 Contents: Page:
1
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
4. 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 for
damage or malfunctions resulting from the non-compliance
with this operating manual.
Descriptions and data given herein are subject to technical
changes.
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 it
by 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
2
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
5. - The valve opens from the top to the bottom in low
leakage operation (unpressurized drain of fluid residues via the
annular gaps in the seat area).
- Separation of two line passages by two balanced and
independently operating valve slides with intervening leakage
chamber.
- 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 by
operation of the air connections:
A1 = lifting of lower shaft
A2 = lifting of upper shaft
Reset by spring force.
3. Mode of operation
3
optical valve position
indication
seat lift
cylinder
main cylinder
actuator
valve housing
cleaning connection
drain pipe
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
6. 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 open
position. A connection between the two pipelines A and B is
realized.
3. Mode of operation
4
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
7. 5
4. Auxiliary Equipment
* Valve position indication
Switches to signal the limit position of the valve shafts
can 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 liability
for any malfunctions resulting therefrom.
- Control Unit
The Control Unit CU2 can be installed on a DA3 valve.
The following designs are possible:
- Assembly tool for middle seal
To simplify the installation of the middle seal, the following
assembly tools are available.
Dimensions Designation Ref.-No..
DN 40, 50, 65 - D3 - 62 51-13-376/17
1,5T, 2T, 2,5T, 3T
DN 80, 100 - D3 - 92 51-13-526/17
4T
DN 125, 150 - D3 - 138 51-13-676/17
Assembly instructions (see page 16).
- For the installation of the control unit on the DA3 valve an adapter
is required. Observe the number of solenoid valves required for the
design of the adapter.
1 solenoid valve 3 solenoid valves
Standard CU CU 21 DA3 / DE3 CU 23 DA3
Ref.No.: 322 000 804 465 322 000 804 466
Valve Net Profibus CU 21 - V DA3 / DE3 CU 23 - V DA3
Ref.No.: 322 000 804 463 322 000 804 464
ASI - Bus CU 21 - ASI DA3 / DE3 CU - ASI DA3
Ref.No.: 322 00 804 580 322 000 804 581
Design of Adapter : 1 solenoid valve 3 solenoid valves
Designation : CU 21 Adapter DA3 / DE3 CU 23 Adapter DA3
Ref.No.: 322 000 801 233 322 000 801 237
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
8. 6
5. Cleaning
With the cleaning of the DELTA DA3 valve, one has to distinguish
between three areas:
The flow areas
The upper and lower passages are cleaned by the passing
cleaning liquid during the cleaning of the connected pipelines.
The seal surfaces
The seal surfaces of the upper area (shaft seal and upper seat
seal) and the lower area (shaft seal and lower seat seal) are
flushed and cleaned by the cleaning liquid by lifting of the individual
valve shafts during the cleaning of the respective passage.
The leakage chamber
The cleaning of the leakage chamber is done by CIP spraying.
CIP cleaning connection (C).
The valve shafts being lifted, the CIP liquid also cleans the
leakage chamber.
The spraying does not produce pressure build-up in the leakage
chamber and can be carried out in closed and in open valve
position. The conduct of the cleaning liquid provides for a
biologically perfect cleaning of the whole leakage chamber.
Under normal conditions
15 valves DN 40 - 100 / 1,5T - 4T
10 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:
DN 40 - 100 / 1,5T - 4T about 1,2 ltr. / 10s
DN 125 - 150 about 5 ltr. / 10s
- Cleaning pressure at CIP cleaning connection : min. 2 bar
max. 5 bar.
cleaning
connection
Cleaning step Lifting cycle CIP spraying
pre-flushing 3 x 10 sec.
caustic flushing 800
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.
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
9. 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 via
the 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 via
the 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.
pressure in bar
DN 40, 50,65
1,5T, 2T,
2,5T, 3T
DN 80, 100
4T
DN 125, 150
Flushing quantity in ml per lifting cycle / 5 sec.
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
0,1 1 2 3 4 5
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
10. 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 (completely
dismantable 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.
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
11. 9
8. Technical Data
max. line pressure : 10 bar
max. operating temperature : 135°C EPDM, HNBR
*VMQ, *FPM
short-term load : 140°C EPDM, HNBR
*VMQ, *FPM
*(no steam)
tightening moment of
stop sleeve (11) : 15Nm
tightening moment of
safety nut (42, 16) at upper
and lower valve shaft : 40Nm
cleaning connection (for hose)
DN 40 - 100 / 1,5T - 4T : 8x1mm
DN 125 - 150 : 10x1mm
air connection (for hose) : 6x1mm
max. pneumatic air pressure : 10 bar
min. pneumatic air pressure : 6 bar
(Use dry and clean pneumatic air, only)
7. Dimensions / Weights
A
L
Z
Y
F
G
F
B
Di
H
installation weight
dimensions in kg
min.
DN A B Di F H L G Y Z
40 378 120 38 100 63 561 163 200 660 13,7
50 384 126 50 100 75 585 163 218 680 13,8
65 392 134 66 100 91 617 163 242 700 14,0
80 419 146 81 120 106 671 188 274 790 19,2
100 429 156 100 120 125 710 188 303 820 20,3
125 507 176 125 150 150 833 236 342 950 46,6
150 519 189 150 150 175 858 236 392 1010 47,5
Tube
1,5T 379 118 35,1 100 63 560 163 197 660 13,7
2T 385 125 47,8 100 75 585 163 216 680 13,7
2,5T 389 131 60,0 100 85 605 163 233 700 14,0
3T 395 137 72,1 100 97 629 163 251 730 14,2
4T 428 155 97,6 120 125 708 188 301 820 20,3
dimensions in mm
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
UK
13. 11
- The maintenance intervals are different depending on the
application and are to be determined by the operator himself
carrying 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 51-13-100/17.
- Exchange of seals according to service instructions.
- Assembly of the valve according to service instructions.
- Provide all seals with a thin layer of grease before their
installation.
Recommendation:
APV food grade grease for EPDM, HNBR and FPM (Viton)
(0,75 kg /can - ref.-No. 000 70-01-019/93)
(60 g /tube - ref.-No. 000 70-01-018/93)
APV food grade grease for VMQ (Silicone)
(0,60 kg /can - ref.-No. 000 70-01-017/93)
(60 g /tube - ref.-No. 000 70-01-016/93)
Recommendation for actuator:
APV pneumatic grease:
(25 ml /tube - ref.-No. 000 70-01-008/93)
11. Service Instructions
The item numbers refer to the spare parts list drawings
DIN: 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
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
14. 12
11.2 Dismantling of the product-wetted seals (servicing)
a. Remove the lower and upper housing seal (32) from the
valve 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 and
pull 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).
11. Service Instructions
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
15. 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 housing
flange (see page 15).
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 between
PTFE 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)!!
11. Service Instructions
seat ring 37
seat seal 36
groove
Ill.X
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
16. 14
11. Service Instructions
e. Insert the middle seal (38) into the lower shaft (3) by means of the
assembly tool (see page 16).
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 safety
nut (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 as
described in chapter 11.2.
11.5 Installation of the valve insert
a. Carefully place the valve insert in the valve housing until the
screw stops (see 11.1e).
b. Remove stop screw and carefully press the valve insert into the
housing.
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 area
medium air connection B : valve open
lower 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).
42
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
17. 15
12.1 Assembly tool for lower shaft seal, items 33, 34
For a simple disassembly and assembly of the lower shaft seal
a universal tool (ref.-No. 000 51-13-100/1) 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 impossible as 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 the
housing into the lower housing (fig. 1).
c) Pull the PTFE into a round shape by means of the assembly
mandril (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
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
18. 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 it
over 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 vent
is 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
lower
valve shaft
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
19. 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 drawings
DIN - 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 position 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 position open
* Leakage at the inner side of the lower shaft (3):
replace middle seal (38).
14. Spare Parts Lists and Lubrication Chart
(see annex)
UK
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2
20. Rev. 2
BA DA3 0000002
Ident-No.: H179 518
UK
APV Products
Zechenstraße 49
D-59425 Unna
Germany
T: +49(0) 23 03/ 108-0
F: +49(0) 23 03 / 108-210
Internet: www.apv.invensys.com Process to Boardroom Automation sm
Double Seat Valve
DELTA DA3+
Operating Manual: Rev. 2