Alfalaval LKAP User manual

ESE01993-EN6 2016-07
Original manual
Instruction Manual
LKAP Air-Operated Valve

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. General installation ................................................................................ 7
3.3. Welding ............................................................................................ 9
3.4. Recycling information ............................................................................. 10
4. Operation ............................................................................................... 11
4.1. General operation ................................................................................. 11
4.2. Fault finding ....................................................................................... 11
4.3. Recommended cleaning ......................................................................... 12
5. Maintenance ........................................................................................... 13
5.1. General maintenance ............................................................................. 13
5.2. Dismantling ........................................................................................ 14
5.3. Assembly .......................................................................................... 16
6. Technical data ......................................................................................... 19
6.1. Technical data ..................................................................................... 19
7. Parts list and service kits ............................................................................ 21
7.1. LKAP-V and LKAP-T air-operated valves with welding ends ................................. 22
3

1 EC Declaration of conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval KoldingA/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
LKAP
Type
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A.
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2016-06-01
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
Alwaysreadthemanualbeforeusingthevalve!
WARNING
Indicates that special procedures must be followed to avoid serious 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.
2.2 Warning signs
General warning:
Caustic agents:
5

2 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.
2.3 Safety precautions
Installation:
Always observe the technical data (see section 6 Technical data)
Always release compressed air after use.
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
!
Operation:
Never dismantle the valve with valve and pipelines under pressure.
Never dismantlethevalvewhenitishot.
Always observe the technical data (see section 6 Technical data)
Always release compressed air after use.
Never touch the valve or the pipelines when processing hot liquids or when sterilizing
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air.
!
Always handle lye and acid with great care
Maintenance:
-Always observe the technical data (see section 6 Technical data)
-Always release compressed air after use
- The valve must never be hot when servicing it
- The valve/actuator and the pipelines must never be pressurised when servicing the valve/ actuator
-Never stick your fingers through the valve ports if the actuator is supplied with compressed air.
-Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air.
!
Transportation:
Always secure that compressed air is released
Always secure that all connections is disconnected before attempt to remove the valve from the installation
Always drain liquid out of valves before transportation
Always used predesigned lifting points if defined
Always secure sufficient fixing of the valve during transportation - if special designed packaging material is available it
must be used
6

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
LKAP-V: Valve body wit two valve ports.
LKAP-T: Valve body with three valve ports.
3.1 Unpacking/delivery
Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery:
1. Complete valve, LKAP-V or LKAP-T
2. Delivery note
3. Instruction manual
Step 2
1. Clean the valve for possible packing materials
2. Inspect the valve for visible transport damage
3. Avoid damaging the valve
3.2 General installation
Step 1
Always read the technical data carefully.
See section 6 Technical data
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
Step 2
Flow direction:
To avoid pressure shocks it is recommended to install the valve
with inlet through the bottom connection.
-A:Inlet
-B:Outlet A
B
TD 402-034_1
A
B
TD 402-035_1
Step 3
Avoid stressing the valve.
-Vibrations
- Thermal expansion of the tubes
- Excessive welding
- Overloading of the pipelines
TD402-018_1
Risk of damage!
7

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
NO = Normally open.
NC = Normally closed.
Step 4
Fittings:
Ensure that the connections are tight (remember seal rings).
TD402-019_1
Step 5
Air connection: R 1/8” (BSP). NO
Air
NC
TD402-013_1
8

3 Installation
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
1. Turn air cylinder (2) anticlockwise by hand with a strap wrench
or with a spanner.
2. Remove the air cylinder from valve body (15).
Step 2
Remove spring (5) and the rest of the internal valve parts from
valve body (15).
Step 3
1. Weld valve body (15) into the pipelines
2. Maintain the minimum clearance so that the internal valve parts
can be removed.
Weld carefully * = incl. inducation
Step 4
Assemble the valve in accordance with the instructions in section 5.3 Assembly
9

3 Installation
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits.
Check the valve for smooth operation after welding.
Step 5
Pre-use check:
1. Supply compressed air to the valve
2. Open and close the valve several times to ensure that it
operates smoothly.
Pay special attention to the warnings!
3.4 Recycling information
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
Maintenance
- During maintenance oil and wear parts in the machine are replaced.
- All metal should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non metal wear parts must be taken care of in agreement with local regulations.
Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be considered and death with in a proper manner. When in doubt, or in the
absence of local regulations, please contact the local Alfa Laval sales company.
10

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
Pay attention to possible faults.
The items refer to the drawings and the parts list in section 7 Parts list and service kits
4.1 General operation
Step 1
Always read the technical data thoroughly.
(see section 6 Technical data)
Always release compressed air after use.
CAUTION
Alfa Laval cannot be held responsible for incorrect
operation.
Step 2
Never touch the valve or the pipelines when processing hot liquids
or when sterilising. Burning danger!
4.2 Fault finding
NOTE
Study the maintenance instructions carefully before replacing worn parts - see section 5 Maintenance
Problem Cause/result Repair
Product leakage through
the drain holes Worn/product affected lip seal (11) Replace the lip seal
Select a different rubber grade
Leakage at the valve plug Worn/product affected O-ring (13) Replace the O-ring
Select a different rubber grade
Air leakage through the drain holes Worn actuator O-rings Replace the O-rings
Air leakage between air cylinder (2)
and valve body (15),
(threaded connection)
Worn O-ring (9)
Loose air cylinder (2)
Replace the O-ring
Tighten the air cylinder
11

4Operation
The valve is designed for cleaning in place (CIP).
CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda. HNO3 = Nitric acid.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
Never touch the valve or the pipelines when sterilising.
Burning danger!
Step 3
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70oC(158
oF) 2. 0.5% by weight HNO3at 70oC (158oF)
1kg(2.2l
bs)
NaOH +100 l (26.4gal)
water =Cleaning agent. 0.7 l (0.18gal)
53% HNO3+100 l (26.4gal)
water =Cleaning agent.
2.2l(0.58gal)
33% NaOH +100 l (26.4 gal) water = Cleaningagent.
Step 4
1. Avoid excessive concentration of the cleaning agent.
⇒Dose gradually
2. Adjust the cleaning flow to the process.
⇒Sterilisation of milk/viscous liquids
⇒Increase the cleaning flow
3. Always rinse well with clean water after the cleaning.
CAUTION! The cleaning agents must be stored/disposed of in
accordance with current rules/directives.
Always rinse!
Clean water Cleaning agents
12

5 Maintenance
Maintain the valve and the actuator carefully.
Study the instructions carefully and pay special attention to the warnings!
Always keep service kits in stock.
Check the valve for smooth operation after service.
5.1 General maintenance
Step 1
Always read the technical data carefully.
See section 6 Technical data
Always release compressed air after use.
NOTE
All scrap must be stored/discharged in accordance
with current rules/directives.
Step 2
Never service the valve when it is hot.
The valve/actuator and the pipelines must never be pressurised
when servicing the valve/actuator.
Atmospheric
pressure
required!
Burning
danger!
Recommended spare parts:
Service kits (see section 7 Parts list and service kits).
Order service kits from the service kits list (see section 7 Parts list and service kits).
Valve lip seal Valve O-rings Actuators O-rings
Preventive maintenance Replace after 12 months Replace when replacing
the lip seal Replace after 5 years
Maintenance after leakage
(leakage normally
starts slowly)
Replace at the end
of the day
Replace when replacing
the lip seal Replace when necessary
Planned maintenance
- Regular inspection for
leakage and smooth
operation
- Keep a record of the valve
- Use the statistics for
planning of inspections
Replace after leakage
- Replacing when replacing
the lip seal
- Regular inspection for
leakage
and smooth operation
- Keep a record of the valve
- Use the statistics for
planning of inspections
Replace after air leakage
Lubrication Before fitting - Silicone grease or
silicone oil None Before fitting
Grease or oil
13

5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits
5.2 Dismantling
Step 1
1. Turn air cylinder (2) anticlockwise by hand with a strap wrench
or with a spanner
2. Remove the air cylinder from valve body (15)
3. Pull out O-ring (3) from the air cylinder
Step 2
Remove spring (5) and the rest of the internal parts from valve
body (15).
Step 3
1. Turn nut (4) anticlockwise and remove it from valve plug unit
(12, 14)
2. Remove screw (1) from the nut
14

5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits
Step 4
1. Separate piston (6) from valve plug unit (12, 14)
2. Pull off O-ring (7) from the piston
Step 5
1. Slide off bottom piece (10) from valve plug unit (12, 14)
2. Remove O-rings (8, 9) from the bottom piece
Step 6
Pull off lip seal (11) from valve plug unit (12, 14).
15

5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits.
Lubricate the rubber seals before fitting them.
Step 7
1. Remove hollow spindle (12) from valve spindle (14)
2. Pull out O-ring (13) from the hollow spindle
5.3 Assembly
Step 1
1. Fit O-ring (13) in hollow spindle (12)
2. Slide the hollow spindle onto valve spindle (14)
Step 2
Fit lip seal (11) on valve plug unit (12, 14)
16

5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits.
Lubricate the rubber seals before fitting them.
Step 3
1. Fit O-rings (8, 9) into the grooves of bottom piece (10)
2. Slide the bottom piece onto valve plug unit (12, 14)
Step 4
1. Fit O-ring (7) on piston (6)
2. Guide the piston onto valve plug unit (12, 14)
Step 5
1. Fit screw (1) in indication nut (4)
2. Guide the indication nut onto valve plug unit (12, 14), turn it
clockwise and tighten
17

5 Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list in section 7 Parts list and service kits.
Lubricate the rubber seals before fitting them.
Step 6
1. Position spring (5) in the groove of piston (6)
2. Fit valve plug unit (12, 14) with the internal parts into valve
body (15)
Step 7
1. Slide O-ring (3) into the groove of air cylinder (2)
2. Fit the air cylinder on valve body (15), turn it clockwise and
tighten by hand with a strap wrench or with a spanner
NOTE!
Fix bottom piece (10) by means of two ø6mm mandrels so that a
free discharge from the drain holes is maintained.
Step 8
Pre-use check:
1. Supply compressed air to the valve
2. Open and close the valve several times to ensure that it
operates smoothly
Pay special attention to the warnings!
18

6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.
NO = Normally open.
NC = Normally closed.
6.1 Technical data
The valve is operated by means of compressed air and has spring return. It has few and simple moving parts which results in
a very reliable valve.
Standard Design LKAP consists of actuator with air cylinder and piston, double lipseal for stem, stem unit with replaceable
O-ring in the plug, and valve body with welding connections.
It has visual indication of the valve position and is available with 2 (LKAP-V) or 3 ports (LKAP-T).
Data- valve/actuator
Max. product pressure 1000 kPa (10 bar)
Max. recommended pressure the plug (NC) 600 kPa (6 bar)
Flow Kv (∆p=1bar) 9m
3/h
Temperature range -10oC to + 140oC(EPDM).
Min. air pressure 500 kPa (5 bar)
Materials
Product wetted steel parts AISI 316L
Finish Semi bright
Air cylinder AISI 304
Product wetted parts Nitrile (NBR), (standard)
Other seals Nitrile (NBR)
Alternative product wetted seals EPDM and Fluorinated rubber (FPM)
A bracket for standard M12 sensors is available for the LKAP valve (see ordering leaflet)
Weight (kg)
Size 25 mm
Weight (kg) 2.5
Noise
One meter away from - and 1.6 meter above the exhaust the noise level of a valve actuator will be approximately 77db(A) without
noise damper and approximately 72 db (A) with damper - Measured at 7 bars air-pressure.
19

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20