Alfalaval LKB Series User manual

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Instra

IM70730-GB5 1999-06
Instruction Manual
LKB Automatic or Manual Butterfly Valve
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Name Title
Company Signature
Alfa Laval
6000 Kolding
[phone]
Company Name
Address
Phone No.
hereby declare that
Denomination Type Year
Declaration of Conformity
The designating company
Designation
Was manufactured in conformity with the provisions in the COUNCIL DIRECTIVE of 4 June
989 on mutual approximation of the laws of the Member States on the safety of machines (89/
392/EEC as amended by directives 9 /368/EEC and 93/44/EEC) with special reference to Annex
of the directive on essential safety and health requirements in relation to the construction
and manufacture of machines.
Bjarne Søndergaard Vice Pre ident, R & D
Alfa Laval
Automatic or Manual Butterfly Valve LKB
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1
This manual is divided into main sections. - See
below.
Table of contents
Safety
Installation
Operation
Maintenance
Technical data
1. Important information ................................. 2
2. Warning signs ........................................... 2
3. Safety precautions .................................... 3
1. Unpacking/ Delivery ................................... 4
2. General installation ...................................
3. Welding .................................................... 6
4. Fitting actuator/bracket/handle .................. 7
. Indication and control equipment ............... 8
1. Operation .................................................. 9
2. Fault finding ............................................ 10
3. Recommended cleaning .......................... 11
1. General maintenance .............................. 12
2. Dismantling of valve - LKB/LKB-2 ............ 14
3. Assembly of valve - LKB/LKB-2 ............... 1
4. Dismantling of valve - LKB-F .................... 16
. Assembly of valve - LKB-F ...................... 17
6. Dismantling of actuator ........................... 18
7. Assembly of actuator .............................. 19
1. Technical data......................................... 20
1. Parts list
- LKB/LKB-2/LKB-F .......................... 22+24
- Handles ......................................... 26+28
- LKLA/LKLA-T, ø8 mm ................... 30+32
- LKLA/LKLA-T, ø133mm ................. 34+36
2. Exploded drawing
- LKB/LKB-2/LKB-F ................................ 23
- Handles ............................................... 27
- LKLA/LKLA-T, ø8 mm ......................... 31
- LKLA/LKLA-T, ø133mm ....................... 3
3. Drawing
- LKB/LKB-2/LKB-F ................................ 2
- Handles ............................................... 29
- LKLA/LKLA-T, ø8 mm ......................... 33
- LKLA/LKLA-T, ø133mm ....................... 37
Spare Parts
Drawings/Parts list
Appendix
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2
Indicates that special procedures must be fol-
lowed to avoid severe personal injury.
Indicates that special procedures must be fol-
lowed to avoid damage to the valve.
Indicates important information to simplify
practices or to make them clearer.
WARNING! :
CAUTION! :
NOTE! :
:
:
General warning.
Caustic agents.
2. Warning signs
Safety
Unsafe practices and other important information are
emphasized in this manual.
Warnings are emphasized by means of special signs.
1. Important information
Always read the manual before usin the valve!
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. Safety precautions
Installation:
:
Operation
:
:
:
:
Maintenance:
:
:
:
:
:
:
All warnings in the manual are summarized on this
page.
" ushrooms" = Fastening connections on the end
cap.
Pay special attention to the instructions below so that
severe personal injury or damage to the valve are
avoided.
Safety
- Always observe the technical data (see page
20).
- Always release compressed air after use.
- Never touch the coupling between the valve
body and the actuator if compressed air is sup-
plied to the actuator.
Always observe the technical data (see page 20).
Never touch the valve or the pipelines when pro-
cessing hot liquids or when sterilizing.
Never touch the coupling between the valve body
and the actuator if compressed air is supplied to
the actuator.
Always handle lye and acid with great care.
-Always observe the technical data (see page
20)
-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 valve is supplied with compressed air.
Never touch the coupling between the valve body
and the actuator if compressed air is supplied to
the actuator.
The actuator springs are not caged (ø8 mm,
NC/NO).
- Never use compressed air for removing the
end cap of the actuator.
- Always fit the end cap with the mushrooms
turned outwards and position it correctly be-
fore supplying compressed air to the actuator.
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4
1
3
5
4
2
Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
The items refer to the drawings and parts list on the
pages 22-25.
The valve is supplied as separate parts as standard
(for welding).
The valve is assembled before delivery, if it is
supplied with fittings (LKB/LKB-2).
1. Unpacking/Delivery
NOTE!
We cannot be held responsible for incorrect
unpacking.
Separate parts for welding!
Check the delivery:
1. Complete valve (see 2).
2. Complete actuator, if supplied (see 3).
3. Bracket for actuator, if supplied (see 3).
4. Complete handle, if supplied.
. Delivery note.
6. Instruction manual.
Standard delivery of valve parts:
1. Two valve body halves (1).
2. Valve disc (2) fitted in seal ring ( ).
3. Two bushes (3.4) fitted on the disc stem.
4. A set of screws and nuts (6).
. Two Flanges (7) and two flange seal rings
(8), (LKB-F).
LKLA - ø133mm
Coupling
elivery of actuator and bracket:
1. Complete actuator with coupling and acti-
vating ring (ø8 mm) or indication pin
(ø133mm).
2. Bracket with screws for the actuator.
Bracket with
screws
Remove
packing
materials!
Valve
Inspection!
1. Inspect the valve/valve parts for visible
transport damages.
2. Inspect the handle or the actuator, if sup-
plied.
Valve
Caution!
1. Avoid damaging the valve/valve parts.
2. Avoid damaging the handle or the actuator,
if supplied.
Valve
1. Clean the valve/valve parts for possible
packing materials.
2. Clean the handle or the actuator, if supplied.
Handle
Actuator
Handle
Actuator
Handle
Actuator
LKB-F (only for welding)LKB/LKB-2
LKLA - ø8 mm
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5
1
3
5
4
2
6
Study the instructions carefully.
The valve has welding ends as standard but can also
be supplied with fittings (not LKB-F).
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
2. General installation
Installation
Air connection of actuator:
Connect compressed air correctly.
Pay special attention to the warnings!
NC NO A/A
Air Air Air
R1/8"(BSP)
Position of actuator:
Position the water rejector on the actuator
correctly. (The actuator can be installed in any
position).
Turn the ventilation
opening downwards!
Fittings:
Ensure that the connections are tight.
Remember
seal rings!
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Risk of
damage!
NOTE!
We cannot be held responsible for incorrect
installation.
-Always observe the technical data
(see page 20).
-Always release compressed air after
use.
-Never touch the coupling between the
valve body and the actuator if compres-
sed air is supplied to the actuator.
Pre-use check:
Open and close the valve several times to
ensure that the valve disc moves smoothly
against the sealring.
Pay special attention to the warnings!
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6
Study the instructions carefully.
The valve is supplied as separate parts to facilitate
the welding.
LKB: For ISO tubes.
LKB-2: For DIN tubes.
LKB-F: With flange connection.
. Welding - LKB/LKB-2
Installation
1. Weld the valve body halves into the pipe-
lines.
2. Maintain the minimum clearance (A) so that
the actuator can be removed.
3. If welding both valve body halves, ensure
that they can be moved axially B1 mm, so
that the valve parts can be removed.
4. Assemble the valve in accordance with the
instructions 1- on page 1 after the weld-
ing.
Pre-use check - LKB/LKB-2/LKB-F:
Open and close the valve several times to
ensure that the valve disc moves smoothly
against the seal ring.
Pay special attention to the warnings!
. Welding - LKB-F
1. Weld the flanges into the pipelines.
2. Maintain the minimum clearances (A and
B2) so that the actuator and the valve parts
can be removed.
3. Assemble the valve in accordance with the
instructions 1- on page 17 after the
welding.
B1(mm) B2(mm)
1" 20 43
1½" 20 43
2" 20 47
2½" 24 46
3" 24 59
4" 37 59
DN25 20 43
DN32 20 43
DN40 20 43
DN50 20 47
DN65 24 59
DN80 23 59
DN100 37 59
DN125 40 63
DN250 41 79
A(mm) Ø85 Ø133
LKLA LKLA-T LKLA LKLA-T
1" 245
1½" 245
2" 255
2½" 265
3" 265
4" 290 +172 420 +172
DN25 245 (incl. (incl.
DN32 245 t p t p
DN40 250 unit) unit)
DN50 260
DN65 270
DN80 275
DN100 290 420
DN125 315 440
DN250 325 445
Caution!
A
B1
A
B2
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7
1
3
5
4
2
6
Installation
Study the instructions carefully and pay special
attention to the warnings!
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
4. Fitting actuator/bracket/handle on the valve (optional extras)
Handle/indication:
1. Fit the standard handle on the valve so that
the screw can enter the hole in the disc
connection.
2. Fit the handle with position indication as
shown and in accordance with the instruc-
tions 3-4 on page 1 .
Handle with
position
indication
Standard
handle
Pre-use check:
Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Actuator/bracket - NO:
1. Ensure that the valve is open by checking
the position of the groove of the disc stem
top.
2. Fit the actuator/bracket in accordance with
instruction 4 on page 1 .
Actuator/bracket - A/A:
1. Ensure that the valve is open by checking
the position of the groove of the disc stem
top.
2. Supply compressed air to the actuator.
3. Fit the actuator/bracket in accordance with
instruction 4 on page 1 .
Actuator/bracket - NC:
1. Ensure that the valve is closed by checking
the position of the groove of the disc stem
top.
2. Fit the actuator/bracket in accordance with
instruction 4 on page 1 .
Screw for
bracket
Bracket
Drain hole
Direction
of rotation
Activating
ring/ indica-
tion pin
No pressure!
Bracket/indication:
1. Fit the bracket as shown.
2. Fit and tighten the screws.
3. Fit the activating ring/indication pin as
shown.
NC actuator
Closed!
Open!
NO actuator
No pressure!
A/A actuator
Air pressure!
Open!
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8
Wiring diagram!
Installation
3
5
12
4
6
Turn the
drain holes
downwards!
1. Fit the indication unit on the bracket.
2. Tighten the screws.
Study the instructions carefully.
LKLA-T: For top units LKT-N and LKT-S.
Activating ring: For ø85mm actuator.
Indication pin: For ø133mm actuator.
Activating screw: For ø133mm actuator.
5. Indication and control equipment (optional extras)
Turn the cable outlet
downwards!
Tighten screw (6) firmly.
NOTE!
The cable gland with seal ring (3) should be
sealed with silicone rubber under extreme condi-
tions.
CAUTION!
The indication and control equipment must be
electrically installed by authorized personnel.
- Indication unit:
(See the instructions on the unit and on the
packing).
-ThinkTop®:
(See the separate instruction manuals).
NOTE!
Assemble the cable socket as shown on the
plastic bag.
Parts: (See the plastic bag)
1. Gland screw.
2. Gland washer.
3. Seal ring.
4. Hood.
. Insert.
6. Screw.
7. Seal.
Connect the cable as shown in the wiring diagram
on the indication unit.
ø85mm
Common 1
3 Closed
valve
2 Open
1. Fit the bracket, the activating ring/indica
tion pin and the actuator/handle corretly
before installing the indication unit.
Pay special attention to the warnings!
(See instructions 1-6 on page 7).
2. Fit the activating screw correctly
(ø133mm).
LKLA - ø133mm
LKLA - ø8 mm
Screw
Ring
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9
Never touch the valve or the pipelines
when processing hot liquids or when
sterilizing.
12
3
Always observe the technical data (see
page 20).
5
4
6
Operation
Study the instructions carefully and pay special
attention to the warnings!
1. Operation
The valve is automatically or manually operated by
means of an actuator or a handle.
NOTE!
We cannot be held responsible for incorrect
operation.
Air
Rotating parts!
Never touch the coupling between the
valve body and the actuator if compressed
air is supplied to the actuator.
Closed valve
Closed valve
Open valve Open valve
Operation by means of standard handle:
1. Manual on/off operation.
2. Pull the handle outwards while rotating it.
NOTE!
This also applies for the Lockable Multiposition
Handle.
Air
Operation by means of actuator:
Automatic on/off operation by means of com-
pressed air.
Closed valve
Closed valve
Open valve Open valve
Operation by means of regulating handle:
1. Manual flow regulation because of infinite
locking positions.
2. Loosen the handle, rotate it and tighten
again.
Burning
danger!
Rotating parts!
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10
Problem Cause/result Repair
- External leakage - Worn seal ring Replace the seal
- Internal leakage - Worn flange seal ring (LKB-F) ring and the bushes
by closed valve
(normal wear)
- External leakage - High pressure - Replace by a seal ring
- Internal leakage - High temperature of a different rubber
by closed valve - Aggressive liquids grade
(too early) - Many activations - Change the operation con-
ditions
- Difficult to Incorrect seal ring Replace by a seal ring
open/close (swelling) of a different rubber grade
- Damage of disc
connection
(high torque)
Difficult to - 900 displacement - Fit correctly
open/close of the actuator (see page 7)
- Incorrect actuator - Change from NC
function (NC,NO) to NO or vice
versa
- Worn actuator - Replace the
bearings bearings
- Dirt penetration - Service the actuator
into the actuator
Operation
Pay attention to possible break-down.
Study the instructions carefully.
LKB-F: With flange connection.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
2. Fault finding
NOTE!
Study the maintenance instructions carefully
before replacing worn parts. - See page 11!
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11
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 700C.
2. 0. % by weight HNO3 at 700C.
. Recommended cleaning
Caustic danger!
1
3
5
Always!
4
6
1 kg + 100 l = Cleaning agent.
NaOH water
2.2 l + 100 l = Cleaning agent.
33% NaOH water
0.7 l + 100 l = Cleaning agent.
3% HNO3water
Always use Always use
rubber gloves! protective goggles!
Always handle lye and acid with great
care.
Never touch the valve or the pipelines
when sterilizing.
1. Avoid excessive concentration of the clean-
ing agent
Þ ose gradually!
2. Adjust the cleaning flow to the process
Þ Sterilization of milk/viscous liquids
Þ Increase the cleaning flow!
NOTE!
The cleaning agents must be stored/discharged
in accordance with current rules/directives.
Clean water Cleaning
agents
2
Study the instructions carefully and pay special
attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
The valve is designed for cleaning in place (CIP).
CIP = Cleaning In Place.
Operation
Burning
danger!
Always rinse well with clean water after the
cleaning.
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12
Never stick your fingers through the valve
ports if compressed air is supplied to the
actuator.
- The valve must never be hot when
servicing it.
- The valve/actuator and the pipelines
must never be pressurised when ser-
vicing the valve/actuator.
-Always observe the technical data (see
page 20).
- Always release compressed air after
use.
Maintenance
aintain the valve and the actuator carefully.
Study the instructions carefully and pay special
attention to the warnings!
Always keep spare seal rings, rubber seals, bushes
and actuator bearings in stock.
" ushrooms" = Fastening connections on the end
cap.
1. General maintenance
1
3
5
2
4
6
NOTE!
All scrap must be stored/discharged in accor-
dance with current rules/directives.
Air
Cutting
danger!
Springs -
Caution!
Atmospheric
pressure
required!
Burning
danger!
Air
Rotating
parts!
Never touch the coupling between the
valve body and the actuator if compressed
air is supplied to the actuator.
Caution!
Mushrooms
End cap
Actuator size ø85mm (NC/NO):
The actuator springs are not caged.
End cap of actuator:
-Never remove the end cap by using
compressed air.
-Always fit the end cap with the mush-
rooms turned outwards and position it
correctly before supplying compressed
air to the actuator.
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1
Maintenance
aintain the valve and the actuator carefully.
Study the instructions carefully.
Always keep spare seal rings, rubber seals, bushes
and actuator bearings in stock.
1. General maintenance
Orderin spare parts
- Contact the Sales Department.
- Order from the Spare Parts List.
Recommended spare parts: Service kits (see Spare Parts List).
Valve seal rings Valve bushes Actuator Actuator bearings
rubber seals
Preventive Replace after Replace when Replace after
maintenance 12 months replacing the 24 months
valve seal rings
Maintenance Replace by the Replace when Replace when
after leakage end of the day replacing the possible
(leakage normally valve seal rings
starts slowly)
Planned mainte- - Regular in- Replace when - Regular in- Replace when
nance spection for replacing the spection for they become
leakage and valve seal rings leakage and worn
smooth opera- smooth opera-
tion tion
- Keep a record - Keep a record
of the valve of the actuator
- Use the stati- - Use the stati-
stics for plan- stics for plan-
ning of inspec- ning of inspec-
tions tions
Replace after Replace after air
leakage leakage
Lubrication Before fitting None Before fitting When replacing
(use USDA-H1 - Molycote Long actuator rubber
approved) term 2 Plus (D) seals
- Unisilcon L641(*) - Molycote 1132(D) - Molycote Long
- Paraliq (*) (for aggressive term 2 Plus (D)
GTE 703 enviroment) - Molycote 1132 (D)
- Molycote 111 (D) (for aggressive
enviroment)
(*) Klüber lubrication
(D) Dow corning
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14
2
1
3 4
5
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
the pages 22-25.
Handle scrap correctly.
LKB: For ISO tubes.
LKB-2: For DIN tubes.
2. Dismantling of valve - LKB/LKB-2
Valve with actuator:
1. Remove screws and nuts (6).
2. Remove the bracket with the actuator.
Valve with handle:
1. Remove the complete handle.
2. Remove screws and nuts (6).
Remove seal ring ( ) together with valve disc
(2). Remove bushes (3,4) from the disc stems.
Remove valve disc (2) from seal ring ( ).
NOTE!
For the valve sizes 2 -38mm and DN2 -40 it is
recommended to remove the valve disc by using a
special service tool.
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15
LKB: For ISO tubes.
LKB-2: For DIN tubes.
Lubricate the seal ring before fitting it.
Lubricate the disc stem before fitting the bushes.
. Assembly of valve - LKB/LKB-2
2
1
34
5
Study the instructions carefully.
The items refer to the drawings and the parts list on
the pages 22-25.
Maintenance
1. Fit bushes (3,4) on the disc stem.
2. Fit seal ring ( ) together with valve disc (2)
between the two valve body halves (1).
CAUTION!
Rotate the valve disc so that the valve is open
before tightening screws and nuts (6).
Valve with handle:
1. Fit screws and nuts (6) and torque tighten in
accordance with the requirements (see ).
2. Fit the complete handle on the disc connec-
tion and tighten the screw on the handle.
NOTE!
This also applies for the Lockable Multiposition
Handle.
Fit correctly!
(See page 7)
Valve with actuator:
1. Fit the actuator with the bracket so that the
disc connection enters the coupling
(see page 7).
2. Fit screws and nuts (6) and torque
tighten in accordance with the requirements
so that the bracket is fixed to the valve
(see ).
25mm 38mm 51mm 63.5mm 76mm 101.6mm
Valve size DN 25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150
Allen Key 5mm 5mm 5mm 6mm 6mm 6mm 8mm 8mm 8mm
Recomm.Torque 18Nm 18Nm 18Nm 20Nm 20Nm 20Nm 38Nm 38Nm 38Nm
Pre-use check:
Check that the valve disc moves smoothly
against the seal ring.
Pay special attention to the warnings!
Tools/torque values for assembly of the valve
body halves:
1. Lubricate the pin holes in seal ring ( ),
(important for Silicone and Viton).
2. Fit valve disc (2) in the seal ring ( ).
NOTE!
For the valve sizes 2 -38mm and DN2 -40 it is
recommended to fit the valve disc by using a spe-
cial service tool.
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16
Remove valve disc (2) from seal ring ( ).
NOTE!
For the valve sizes 2 -38mm and DN2 -40 it is
recommended to remove the valve disc by using a
special service tool.
2
1
3
5
Maintenance
4
Study the instructions carefully.
The items refer to the drawings and the parts list on
the pages 22-25.
Handle scrap correctly.
LKB-F: With flange connection.
4. Dismantling of valve - LKB-F
1. Loosen the two upper screws and nuts (6).
2. Loosen and remove the two lower screws
and nuts (6).
3. Remove the valve unit from flanges (7).
1. Remove the two upper screws and nuts (6),
(4 nuts)
2. If supplied, remove the actuator from the
valve body unit.
3. If supplied loosen the screw and remove the
handle from the valve body unit.
1. Loosen and remove the two center screws
and nuts (6).
2. Remove seal ring ( ) together with valve
disc (2).
3. Remove flange seal rings (8). Remove bushes (3,4) from the disc stems.
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17
Pre-use check:
Check that the valve disc moves smoothly
against the seal ring.
Pay special attention to the warnings!
Tools/torque values for assembly of the valve
body halves:
2
1
3
5
4
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
the pages 22-25.
LKB-F: With flange connection,
Lubricate the seal rings before fitting them.
Lubricate the disc stem before fitting the bushes.
5. Assembly of valve - LKB-F
1. Lubricate flange seal rings (8) with
water and fit them.
2. Fit seal ring ( ) together with valve disc (2)
between the valve body halves (1).
3. Fit and tighten the two center screws and
nuts (6).
CAUTION!
Rotate the valve disc so that the valve is open
before tightening screws and nuts (6).
1. If supplied, fit the handle and tighten the
screw.
2. If supplied, fit the actuator.
3. Fit the two upper screws and nuts (6),
(4 nuts).
1. Fit the valve unit between flanges (7).
2. Fit and tighten the two lower screws and
nuts (6).
3. Tighten the two upper screws and nuts (6).
25mm 38mm 51mm 63.5mm 76mm 101.6mm
Valve size DN 25 DN32 DN40 DN50 DN65 DN80 DN100 DN125 DN150
Spanner flats 10mm 10mm 10mm 13mm 13mm 13mm 17mm 17mm 17mm
Recomm.Torque 18Nm 18Nm 18Nm 20Nm 20Nm 20Nm 38Nm 38Nm 38Nm
1. Lubricate the pin holes in seal ring ( ),
(inportant for Silicone and Viton).
2. Fit valve disc (2) on seal ring ( ).
3. Fit bushes (3,4) in the disc stem.
NOTE!
For the valve size 2 -38mm and DN2 -40 it is
recommended to fit the valve disc by using a
special service tool.
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