Alfalaval LKAP User manual

ESE01993-EN72022-10
Originalmanual
InstructionManual
LKAPAir-OperatedValve

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.Declarationsofconformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetprecautions................................................................................7
3.Installation....................................................................................8
3.1.Unpacking/deliver...............................................................................8
3.2.Generalinstallation................................................................................8
3.3.Welding............................................................................................10
3.4.Recclinginformation.............................................................................11
4.Operation.....................................................................................12
4.1.Generaloperation.................................................................................12
4.2.Faultfinding.......................................................................................12
4.3.Recommendedcleaning.........................................................................13
5.Maintenance..................................................................................14
5.1.Generalmaintenance.............................................................................14
5.2.Dismantling........................................................................................15
5.3.Assembl..........................................................................................17
6.Technicaldata................................................................................20
6.1.Technicaldata.....................................................................................20
7.Partslistandservicekits...................................................................21
7.1.LKAP-VandLKAP-Tair-operatedvalveswithweldingends.................................22
3

1Declarationsofconformity
EU EU
EUDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
LKAP
Tpe
isinconformitwiththefollowingdirectiveswithamendments:
-MachinerDirective2006/42/EC
-PressureEquipmentDirective2014/68/EUcategor1andsubjectedtoassessmentprocedureModuleA
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformitreplacesDeclarationofConformitdated2016-06-01
4

1Declarationsofconformity
UK UK
UKDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Valve
Designation
LKAP
Tpe
isinconformitwiththefollowingdirectiveswithamendments:
-TheSupplofMachiner(Safet)Regulations2008
-ThePressureEquipment(Safet)Regulations2016categor1andsubjectedtoassessmentprocedureModuleA
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasizedinthismanual.
Warningsareemphasizedbymeansofspecialsigns.
2.1Importantinformation
Alwas Alwas
Alwasr r read ead eadthe the themanual manual manualbefor befor before e eusing using usingthe the thevalve! valve! valve!
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjur.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothevalve.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimpliforclarifprocedures.
2.2Warningsigns
Generalwarning:
Causticagents:
6

2Safety
Allwarningsinthemanualaresummarizedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothevalveareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Alwas Alwas
Alwasobservethetechnicaldata(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Nevertouchtheclipassemblortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair.
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilizing.
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure.
Never Never
Neverdismantlethevalvewhenitishot.
Operation: Operation:
Operation:
Never Never
Neverdismantlethevalvewithvalveandpipelinesunderpressure.
Never Never
Neverdismantlethevalvewhenitishot.
Alwas Alwas
Alwasobservethetechnicaldata(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse.
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquidsorwhensterilizing
Never Never
Nevertouchtheclipassemblortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair.
Alwas Alwas
Alwashandleleandacidwithgreatcare
Maintenance: Maintenance:
Maintenance:
-Alwas Alwas
Alwasobservethetechnicaldata(seesection6Technicaldata)
-Alwas Alwas
Alwasreleasecompressedairafteruse
-Thevalvemustnever never
neverbehotwhenservicingit
-Thevalve/actuatorandthepipelinesmustneverbepressurisedwhenservicingthevalve/actuator
-Never Never
Neverstickourfingersthroughthevalveportsiftheactuatorissuppliedwithcompressedair.
-Never Never
Nevertouchtheclipassemblortheactuatorpistonrodiftheactuatorissuppliedwithcompressedair.
T T
Transportation: ransportation: ransportation:
Alwas Alwas
Alwassecurethatcompressedairisreleased
Alwas Alwas
Alwassecurethatallconnectionsisdisconnectedbeforeattempttoremovethevalvefromtheinstallation
Alwas Alwas
Alwasdrainliquidoutofvalvesbeforetransportation
Alwas Alwas
Alwasusedpredesignedliftingpointsifdefined
Alwas Alwas
Alwassecuresufficientfixingofthevalveduringtransportation-ifspecialdesignedpackagingmaterialisavailableit
mustbeused
7

3Installation
Theinstructionmanualispartofthedelivery.
Studytheinstructionscarefully.
KAP-V:Valvebodywittwovalveports.
KAP-T:Valvebodywiththreevalveports.
3.1Unpacking/delivery
Unpacking/deliver Unpacking/deliver
Unpacking/deliver
Step Step
Step1 1 1
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
Check Check
Checkthe the thedeliver: deliver: deliver:
1.Completevalve,LKAP-VorLKAP-T
2.Delivernote
3.Instructionmanual
Step Step
Step2 2 2
1.Cleanthevalveforpossiblepackingmaterials
2.Inspectthevalveforvisibletransportdamage
3.Avoiddamagingthevalve
3.2Generalinstallation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatacarefull.
Seesection6Technicaldata
Alwas Alwas
Alwasreleasecompressedairafteruse.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
installation.
Step Step
Step2 2 2
Flow Flow
Flowdir dir direction: ection: ection:
Toavoidpressureshocksitisrecommendedtoinstallthevalve
withinletthroughthebottomconnection.
-A:Inlet
-B:Outlet
Step Step
Step3 3 3
Avoidstressingthevalve.
-Vibrations
-Thermalexpansionofthetubes
-Excessivewelding
-Overloadingofthepipelines
Risk Risk
Riskof of ofdamage! damage! damage!
8

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Thevalvehasweldingendsasstandardbutcanalsobesuppliedwithfittings.
NO=Normallyopen.
NC=Normallyclosed.
Step Step
Step4 4 4
Fittings: Fittings:
Fittings:
Ensurethattheconnectionsaretight(remembersealrings).
Step Step
Step5 5 5
Airconnection:R1/8”(BSP).NO
Air
NC
9

3Installation
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits.
Checkthevalveforsmoothoperationafterwelding.
3.3Welding
Step Step
Step1 1 1
1.Turnairclinder(2)anticlockwisebhandwithastrapwrench
orwithaspanner.
2.Removetheairclinderfromvalvebod(15).
Step Step
Step2 2 2
Removespring(5)andtherestoftheinternalvalvepartsfrom
valvebod(15).
Step Step
Step3 3 3
1.Weldvalvebod(15)intothepipelines
2.Maintaintheminimumclearancesothattheinternalvalveparts
canberemoved.
W W
Weld eld eldcar car carefull efull efull*=incl.inducation
Step Step
Step4 4 4
Assemblethevalveinaccordancewiththeinstructionsinsection5.3Assembl
10

3Installation
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits.
Checkthevalveforsmoothoperationafterwelding.
Step Step
Step5 5 5
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.Supplcompressedairtothevalve
2.Openandclosethevalveseveraltimestoensurethatit
operatessmoothl.
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
3.4Recyclinginformation
Unpacking Unpacking
Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps.
-Woodandcardboardboxescanbereused,reccledorusedforenergrecover.
-Plasticsshouldbereccledorburntatalicensedwasteincinerationplant.
-Metalstrapsshouldbesentformaterialreccling.
Maintenance Maintenance
Maintenance
-Duringmaintenanceoilandwearpartsinthemachinearereplaced.
-Allmetalshouldbesentformaterialreccling.
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialreccling.
-Oilandallnonmetalwearpartsmustbetakencareofinagreementwithlocalregulations.
Scrapping Scrapping
Scrapping
-Atendofuse,theequipmentshallbereccledaccordingtorelevant,localregulations.Besidetheequipmentitself,an
hazardousresiduesfromtheprocessliquidmustbeconsideredanddeathwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactthelocalAlfaLavalsalescompan.
11

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Ensurethatthevalveoperatessmoothly.
Payattentiontopossiblefaults.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits
4.1Generaloperation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.
(seesection6Technicaldata)
Alwas Alwas
Alwasreleasecompressedairafteruse.
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrect
operation.
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhenprocessinghotliquids
orwhensterilising.Bur Bur
Burning ning ningdanger! danger! danger!
4.2Faultnding
NOTE NOTE
NOTE
Studthemaintenanceinstructionscarefullbeforereplacingwornparts-seesection5Maintenance
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRepair Repair
Repair
Productleakagethrough
thedrainholesWorn/productaffectedlipseal(11)Replacethelipseal
Selectadifferentrubbergrade
LeakageatthevalveplugWorn/productaffectedO-ring(13)ReplacetheO-ring
Selectadifferentrubbergrade
AirleakagethroughthedrainholesWornactuatorO-ringsReplacetheO-rings
Airleakagebetweenairclinder(2)
andvalvebod(15),
(threadedconnection)
WornO-ring(9)
Looseairclinder(2)
ReplacetheO-ring
Tightentheairclinder
12

4Operation
Thevalveisdesignedforcleaninginplace(CIP).
CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.HNO3=Nitricacid.
4.3Recommendedcleaning
Step Step
Step1 1 1
Alwas Alwas
Alwashandleleandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Alwas Alwas
Alwasuse
rubbergloves!
Alwas Alwas
Alwasuse
protectivegoggles!
Step Step
Step2 2 2
Never Never
Nevertouchthevalveorthepipelineswhensterilising.
Bur Bur
Burning ning ningdanger! danger! danger!
Step Step
Step3 3 3
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents: agents: agents:
Usecleanwater,freefromclorides.
1.1%bweightNaOHat70oC(158oF)2.0.5%bweightHNO3at70oC(158oF)
1kg(2.2lbs)
NaOH+100l(26.4gal) water=Cleaningagent.0.7l(0.18gal)
53%HNO3+100l(26.4gal) water=Cleaningagent.
2.2l(0.58gal)
33%NaOH+100l(26.4gal) water=Cleaningagent.
Step Step
Step4 4 4
1.Avoidexcessiveconcentrationofthecleaningagent.
⇒Dosegraduall
2.Adjustthecleaningflowtotheprocess.
⇒Sterilisationofmilk/viscousliquids
⇒Increasethecleaningflow
3.Alwas Alwas
Alwasrinsewellwithcleanwaterafterthecleaning.
CAUTION! CAUTION!
CAUTION!Thecleaningagentsmustbestored/disposedofin
accordancewithcurrentrules/directives.
Alwas Alwas
Alwasrinse! rinse! rinse!
CleanwaterCleaningagents
13

5Maintenance
Maintainthevalveandtheactuatorcarefully.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Alwayskeepservicekitsinstock.
Checkthevalveforsmoothoperationafterservice.
5.1Generalmaintenance
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatacarefull.
Seesection6Technicaldata
Alwas Alwas
Alwasreleasecompressedairafteruse.
NOTE NOTE
NOTE
Allscrapmustbestored/dischargedinaccordance
withcurrentrules/directives.
Step Step
Step2 2 2
Never Never
Neverservicethevalvewhenitishot.
Thevalve/actuatorandthepipelinesmustnever never
neverbepressurised
whenservicingthevalve/actuator.
Atmospheric Atmospheric
Atmospheric
pr pr
pressur essur essure e e
r r
requir equir equired! ed! ed!
Bur Bur
Burning ning ning
danger! danger!
danger!
Recommended Recommended
Recommendedspar spar spare e eparts: parts: parts:
Servicekits(seesection7Partslistandservicekits).
Orderservicekitsfromtheservicekitslist(seesection7Partslistandservicekits).
V V
Valve alve alvelip lip lipseal seal sealV V Valve alve alveO O O- - -rings rings ringsActuators Actuators ActuatorsO O O- - -rings rings rings
PreventivemaintenanceReplace Replace
Replaceafter after after12 12 12months months monthsReplace Replace
Replacewhen when whenr r replacing eplacing eplacing
the the
thelip lip lipseal seal sealReplace Replace
Replaceafter after after5 5 5ears ears ears
Maintenanceafterleakage
(leakagenormall
startsslowl)
Replace Replace
Replaceat at atthe the theend end end
of of
ofthe the theda da da
Replace Replace
Replacewhen when whenr r replacing eplacing eplacing
the the
thelip lip lipseal seal sealReplace Replace
Replacewhen when whennecessar necessar necessar
Plannedmaintenance
-Regularinspectionfor
leakageandsmooth
operation
-Keeparecordofthevalve
-Usethestatisticsfor
planningofinspections
Replaceafterleakage
-Replacingwhenreplacing
thelipseal
-Regularinspectionfor
leakage
andsmoothoperation
-Keeparecordofthevalve
-Usethestatisticsfor
planningofinspections
Replaceafterairleakage
LubricationBeforefitting -Siliconegreaseor
siliconeoilNoneBeforefitting
Greaseoroil
14

5Maintenance
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits
5.2Dismantling
Step Step
Step1 1 1
1.Turnairclinder(2)anticlockwisebhandwithastrapwrench
orwithaspanner
2.Removetheairclinderfromvalvebod(15)
3.PulloutO-ring(3)fromtheairclinder
Step Step
Step2 2 2
Removespring(5)andtherestoftheinternalpartsfromvalve
bod(15).
Step Step
Step3 3 3
1.Turnnut(4)anticlockwiseandremoveitfromvalveplugunit
(12,14)
2.Removescrew(1)fromthenut
15

5Maintenance
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits
Step Step
Step4 4 4
1.Separatepiston(6)fromvalveplugunit(12,14)
2.PulloffO-ring(7)fromthepiston
Step Step
Step5 5 5
1.Slideoffbottompiece(10)fromvalveplugunit(12,14)
2.RemoveO-rings(8,9)fromthebottompiece
Step Step
Step6 6 6
Pullofflipseal(11)fromvalveplugunit(12,14).
16

5Maintenance
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits.
ubricatetherubbersealsbeforefittingthem.
Step Step
Step7 7 7
1.Removehollowspindle(12)fromvalvespindle(14)
2.PulloutO-ring(13)fromthehollowspindle
5.3Assembly
Step Step
Step1 1 1
1.FitO-ring(13)inhollowspindle(12)
2.Slidethehollowspindleontovalvespindle(14)
Step Step
Step2 2 2
Fitlipseal(11)onvalveplugunit(12,14)
17

5Maintenance
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits.
ubricatetherubbersealsbeforefittingthem.
Step Step
Step3 3 3
1.FitO-rings(8,9)intothegroovesofbottompiece(10)
2.Slidethebottompieceontovalveplugunit(12,14)
Step Step
Step4 4 4
1.FitO-ring(7)onpiston(6)
2.Guidethepistonontovalveplugunit(12,14)
Step Step
Step5 5 5
1.Fitscrew(1)inindicationnut(4)
2.Guidetheindicationnutontovalveplugunit(12,14),turnit
clockwiseandtighten
Step Step
Step6 6 6
1.Positionspring(5)inthegrooveofpiston(6)
2.Fitvalveplugunit(12,14)withtheinternalpartsintovalve
bod(15)
18

5Maintenance
Studytheinstructionscarefully.
Theitemsrefertothedrawingsandthepartslistinsection7Partslistandservicekits.
ubricatetherubbersealsbeforefittingthem.
Step Step
Step7 7 7
1.SlideO-ring(3)intothegrooveofairclinder(2)
2.Fittheairclinderonvalvebod(15),turnitclockwiseand
tightenbhandwithastrapwrenchorwithaspanner
NOTE! NOTE!
NOTE!
Fixbottompiece(10)bmeansoftwoø6mmmandrelssothata
freedischargefromthedrainholesismaintained.
Step Step
Step8 8 8
Pr Pr
Pre e e- - -use use usecheck: check: check:
1.Supplcompressedairtothevalve
2.Openandclosethevalveseveraltimestoensurethatit
operatessmoothl
Pa Pa
Paspecial special specialattention attention attentionto to tothe the thewar war warnings! nings! nings!
19

6Technicaldata
Itisimportanttoobservethetechnicaldataduringinstallation,operationandmaintenance.
Informthepersonnelaboutthetechnicaldata.
NO=Normallyopen.
NC=Normallyclosed.
6.1Technicaldata
Thevalveisoperatedbmeansofcompressedairandhasspringreturn.Ithasfewandsimplemovingpartswhichresultsin
averreliablevalve.
StandardDesignLKAPconsistsofactuatorwithairclinderandpiston,doublelipsealforstem,stemunitwithreplaceable
O-ringintheplug,andvalvebodwithweldingconnections.
Ithasvisualindicationofthevalvepositionandisavailablewith2(LKAP-V)or3ports(LKAP-T).
Data Data
Data- - -valve/actuator valve/actuator valve/actuator
Max.productpressure1000kPa(10bar)
Max.recommendedpressuretheplug(NC)600kPa(6bar)
FlowKv(∆p=1bar)9m3/h
Temperaturerange-10oCto+140oC(EPDM).
Min.airpressure500kPa(5bar)
Materials Materials
Materials
ProductwettedsteelpartsAISI316L
FinishSemibright
AirclinderAISI304
ProductwettedpartsNitrile(NBR),(standard)
OthersealsNitrile(NBR)
AlternativeproductwettedsealsEPDMandFluorinatedrubber(FPM)
AbracketforstandardM12sensorsisavailablefortheLKAPvalve(seeorderingleaflet)
W W
Weight eight eight(kg)
Size Size
Size25 25
25mm mm mm
Weight(kg)2.5
Noise Noise
Noise
Onemeterawafrom-and1.6meterabovetheexhaustthenoiselevelofavalveactuatorwillbeapproximatel77db(A)without
noisedamperandapproximatel72db(A)withdamper-Measuredat7barsair-pressure.
20