Alfalaval LKLA NC User manual

TD 480-007
TD 480-008
TD 480-009
TD 480-016
ESE01699-EN6 2016-10
Original manual
Instruction Manual
LKB UltraPure Automatic or Manual Butterfly 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 ................................................................................ 8
3.3. Welding ............................................................................................ 9
3.4. Fitting actuator/bracket/handle on the valve (optional extras) ................................ 10
3.5. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation .......................................................................................... 12
4.2. Troubleshooting ................................................................................... 13
4.3. Recommended cleaning ......................................................................... 14
5. Maintenance ........................................................................................... 15
5.1. General maintenance ............................................................................. 15
5.2. Dismantling the valve ............................................................................. 17
5.3. Valve assembly .................................................................................... 18
5.4. Dismantling of actuator ........................................................................... 19
5.5. Assembly of actuator ............................................................................. 20
6. Technical data ......................................................................................... 21
6.1. Technical data ..................................................................................... 21
7. Parts list and service kits ............................................................................ 24
7.1. Drawing ............................................................................................ 24
7.2. LKB UltraPure Butterfly Valve, ISO .............................................................. 25
7.3. LKB UltraPure Butterfly Valve, ASME ........................................................... 27
7.4. LKB UltraPure Butterfly Valve, DIN .............................................................. 29
7.5. LKB lockable multiposition handle for valve .................................................... 31
7.6. LKB handle 1.1 for Butterfly Valve .............................................................. 33
7.7. Handle 1.1 for indication unit .................................................................... 35
7.8. LKLA actuator air/spring (NC-NO) ø85 ......................................................... 37
7.9. LKLA actuator air/air ø85 ........................................................................ 39
7.10.LKLA actuator air/spring (NC-NO) ø133 ........................................................ 41
7.11.LKLA actuator air/air ø133 ....................................................................... 43
7.12.LKLA-T actuator air/spring (NC-NO) ø85 ....................................................... 45
7.13.LKLA-T actuator air/air ø85 ...................................................................... 47
7.14.LKLA-T actuator air/spring (NC-NO) ø133 ..................................................... 49
7.15.LKLA-T actuator air/air ø133 .................................................................... 51
3

1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve actuator
Designation
LKLA NC, LKLA NO, LKLA A/A, LKLA-T NO, LKLA-T NC, LKLA-T A/A
Type
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2012-08-01
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
Always read the manual before using the valve!
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

2Safety
All warnings in the manual are summarized on this page.
”Mushrooms” = Fastening connections on the end cap.
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 read the technical data thoroughly (See chapter 5 Maintenance). !
Always release compressed air after use.
Never touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
Operation
Always read the technical data thoroughly (See chapter 5 Maintenance). !
Never touch the valve or the pipelines when processing 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.
Maintenance
Always observe the technical data thoroughly (See chapter 5 Maintenance). !
Always release compressed air after use.
Never service the valve when it is hot.
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 coupling between the valve body and the actuator if compressed air is supplied to the actuator.
The actuator springs are not caged (ø85 mm, NC/NO).
Never use compressed air for removing the end caps of the actuator.
Always fit the end cap with the “mushrooms” turned outwards and position it correctly before supplying compressed
air to the actuator.
Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on the use of Alfa
Laval genuine spare parts.
Transp ortat ion
Always secure that compressed air is released .
Always secure that all connections is disconnected before attemt 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
mustbeused.
6

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is preassembled before delivery.
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery:
1. Complete valve (see Step 2).
2. Complete actuator, if supplied (see Step 3).
3. Bracket for actuator, if supplied (see Step 3).
4. Complete handle, if supplied.
5. Delivery note.
6. Instruction manual.
Step 2
Standard delivery of valve parts:
1. Two valve body halves (1).
2. Valve disc (2) fitted in seal ring (5).
3. Two bushes (3, 4) fitted on the disc stem.
4. A set of screws and nuts (6).
Separate parts for welding
TD 403-102
152436
Step 3
Delivery of actuator and bracket:
1. Complete actuator with coupling and activating ring (ø85 mm)
or indication pin (ø133 mm).
2. Bracket with screws for the actuator.
3. Water rejector (if not mounted)
LKLA -
ø85mm
Bracket
with screws LKLA - ø133mm
TD403-103
Coupling
Step 4
1. Clean the valve/valve parts for possible packing materials.
2. Clean the handle or the actuator, if supplied.
Handle Valve Actuator
TD 403-090
Remove packing materials!
Step 5
Inspection!
1. Inspect the valve/valve parts for visible transport damage.
2. Inspect the handle or the actuator, if supplied.
Caution!
Avoid damaging the valve/valve parts.
Avoid damaging the handle or the actuator, if supplied.
Handle Valve Actuator
TD 403-090
7

3 Installation
Study the instructions carefully. The valve has welding ends as standard but can also be supplied with fittings.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
3.2 General installation
Step 1
Always read the technical data carefully.
Always release compressed air after use.
Never touch the coupling between the valve body and the actuator if compressed air is supplied to the actuator.
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
Step 2
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
TD 403-091
Step 3
Fittings:
Ensure that the connections are tight.
TD 403-092
Remember seal rings!
Step 4
Position of actuator:
Position the water rejector on the actuator correctly. (The actuator
can be installed in any position).
Turn the ventilation opening downwards!
TD 403-286
Important!
Air Air Air
Air connection of actuator:
Connect compressed air correctly.
Pay special attention to the warnings!
R⅛”(BSP)
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! TD 403-107
NC NO A/A
8

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
LKB UltraPure: for ISO, DIN and ASME tubes
3.3 Welding
Step 1
1. Weld the valve body halves into the pipelines.
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. After welding assemble the valve in accordance with the steps 1-5 in section 5.3 Valve assembly.
Pre-use check
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!
A
(mm)
Ø85 Ø133
Size
LKLA LKLA-T LKLA LKLA-T
B1(mm)
25 mm/1” 245 20
38 mm/1½” 245 20
51 mm/2” 255 20
63.5 mm/2½” 265 24
76.1 mm/3” 265 24
101.6 mm/4” 290 420 37
DN25 245 20
DN32 245 20
DN40 250 20
DN50 260 20
DN65 270 24 Caution!
DN80 275 23
DN100 290
+172
(incl. top unit)
420
+ 172
(incl. top unit)
37
TD 403-088
A
B1
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
3.4 Fitting actuator/bracket/handle on the valve (optional extras)
Step 1
Bracket/indication:
1. Fit the bracket as shown.
2. Fit and tighten the screws.
3. Fit the activating ring/indication pin as shown.
Screw for bracket Direction of
rotation
Bracket
TD 403-121
Drain hole Activating ring/ indication pin
Step 2
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 Step 4 section 5.3
Valve assembly.
NC actuator No pressure!
TD 403-122
Closed
Step 3
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 Step 4 section 5.3
Valve assembly.
NC actuator No pressure!
TD 403-123
Open
Step 4
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 Step 4 section 5.3
Valve assembly
A/A actuator
Air pressure!
TD 403-124
Open
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
Step 5
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 Step 3-Step 4, section 5.3 Valve assembly.
Pre-use check:
Open and close the valve several times to ensure that it operates
smoothly.
Pay special attention to the warnings!
Standard handle Handle with position
indication
3.5 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 parts 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 dealt with in a proper manner. When in doubt, or in the
absence of local regulations, please contact the local Alfa Laval sales company
11

4Operation
Study the instructions carefully and pay special attention to the warnings!
The valve is automatically or manually operated by means of an actuator or a handle.
4.1 Operation
Step 1
Always read the technical data carefully.
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
TD 403-110
Step 3
Never touch the coupling between the valve body and the actuator
if compressed air is supplied to the actuator.
Air
TD 403-111
Rotating parts
Step 4
Operation by means of actuator:
Automatic on/off operation by means of compressed air.
Air
TD 403-111
Rotatingparts
Step 5
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.
Closed valve
Open valve
TD 403-114
Open valve
Closed valve
12

4Operation
Pay attention to possible break-down. Study the instructions carefully.
NC = Normally closed. NO = Normally open. A/A = Air/air activated.
Step 6
Operation by means of regulating handle:
1. Manual flow regulation because of infinite locking positions.
2. Loosen the handle, rotate it and tighten again.
Closed valve
Open valve Open valve
Closed valve
4.2 Troubleshooting
Step 1
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See 5.1 General maintenance
Problem Cause/result Repair
- External leakage
- Internal leakage by closed valve
(normal wear)
- Worn seal ring
- Worn flange seal ring (LKB-F)
Replace the seal ring and the bushes
- External leakage
- Internal leakage by closed valve (too
early)
- High pressure
-Hightemperature
- Aggressive liquids
- Many activations
- Change rubber grade
- Change the operation conditions
- Difficult to open/close
- Damage of disc connection (high
torque)
Incorrect seal ring (swelling) Replace by a seal ring of a different rubber
grade
Difficult to open/close - 90° displacement of the actuator
- Incorrect actuator function (NC,NO)
- Worn actuator bearings
- Dirt penetration into the actuator
- Fit correctly (see 3.4 Fitting
actuator/bracket/handle on the
valve (optional extras))
- ChangefromNCtoNOorviceversa
- Replace the bearings
- Service the actuator
13

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!
TD 403-110
Step 3
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70oC (158oF) 2. 0.5% by weight HNO3at 70oC (158oF)
1kg
(2.2 lbs)
NaOH
+
100 l
(26.4 gal)
water
=Cleaning agent.
0.7 l
(0.2 gal)
53% HNO3
+
100 l
(26.4 gal)
water
=Cleaning agent.
2.2 l
(0.6 gal)
33% NaOH
+
100 l
(26.4 gal)
water
=Cleaning agent.
Step 4
1. Avoid excessive concentration of the cleaning agent.
-Dosegradually.
2. Adjust the cleaning flow to the process.
- Sterilization of milk/viscous liquids.
- Increase the cleaning flow.
3. Always rinse well with clean water after the cleaning.
Always rinse!
Clean water Cleaning agents
Step 5
NOTE
The cleaning agents must be stored/disposed off in accordance with current regulations/directives.
14

5 Maintenance
Maintain the valve and the regulator 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. Always use Alfa Laval genuine spare parts.
”Mushrooms” = Fastening connections on the end cap.
5.1 General maintenance
Step 1
Always read the technical data carefully.
See chapter 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.
Never service the valve with valve and pipelines under pressure.
The valve/actuator and the pipelines must never be pressurised
when servicing the valve/actuator.
Atmospheric
pressure
required!
Burning danger!
TD 403-139
Step 3
Never stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
Air
Cutting danger!
TD 403-112
Step 4
Never touch the coupling between the valve body and the actuator
if compressed air is supplied to the actuator.
Air
TD 403-112
Rotating parts
15

5 Maintenance
Maintain the valve and the regulator 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. Always use Alfa Laval genuine spare parts.
”Mushrooms” = Fastening connections on the end cap.
Step 5
Actuator size ø85 mm (NC/NO):
The actuator springs are not caged.
TD 403-118
Springs
Caution!
Step 6
End cap of actuator:
-Never remove the end cap by using compressed air.
-Always fit the end cap with the “mushrooms” turned outwards
and position it correctly before supplying compressed air to
the actuator.
Caution!
End cap “Mushrooms”
TD 403-113
Recommended spare parts: Service kits (see 7 Parts list and service kits).
Order service kits from the service kits list (see 7 Parts list and service kits)
Ordering spare parts
Contact the Sales Department.
Valve seal rings Valve bushes Actuator rubber seals Actuator bearings
Preventive maintenance Replace after 12
months
Replace when replacing
the valve seal rings
Replace after 24
months
Maintenance after
leakage (leakage
normally starts slowly)
Replace by the end of
the day
Replace when replacing
the valve seal rings
Replace when possible
Planned maintenance - Regular inspection
for leakage and
smooth operation
Replace when replacing
the valve seal rings
- Regular inspection
for leakage and
smooth operation
Replace when they
become worn
- Keep a record of the
valve
- Keep a record of the
actuator
- Use the statistics
for planning of
inspections
- Use the statistics
for planning of
inspections
Replace after leakage Replace after air
leakage
Lubrication Before fitting
(use USDA-H1
approved)
-UnisilconL641(*)
- Paraliq(*) GTE 703
- Molycote 111(D)
None Before fitting
- Molycote Long term
2Plus(Δ)
- Molycote 1132(Δ)
(for aggressive
environment)
When replacing
actuator rubber seals
- Molycote Long term
2Plus(Δ)
- Molycote 1132
(Δ)(foraggressive
environment)
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
LKB UltraPure: For ISO, DIN and ASME tubes.
5.2 Dismantling the valve
Step 1
Valve with actuator:
1. Remove screws and nuts (6).
2. Remove the bracket with the actuator.
TD 403-093
Step 2
Valve with handle:
1. Remove the complete handle.
2. Remove screws and nuts (6).
TD 403-094
Step 3
Remove seal ring (5) together with valve disc (2).
TD 403-096
Step 4
Remove bushes (3, 4) from the disc stems.
TD 403-096
Step 5
Removevalvedisc(2)fromsealring(5).
NOTE!
For the valve sizes 25-38 mm and DN25-40 it is recommended
to remove the valve disc by using a special service tool (item no.
9611981090) TD 403-097
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
LKB UltraPure: For ISO, DIN and ASME tubes.
Lubricate the seal ring before fitting it.
Lubricate the disc stem before fitting the bushes.
5.3 Valve assembly
Step 1
1. Lubricate the pin holes in seal ring (5), (important for Silicone
and Viton).
2. Fit valve disc (2) in the seal ring (5).
NOTE!
For the valve sizes 25-38 mm and DN25-40 it is recommended
to fit the valve disc by using a special service tool (item no.
9611981090).
TD 403-265
Step 2
1. Fit bushes (3,4) on the disc stem.
2. Fit seal ring (5) 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).
TD 403-266
Step 3
Valve with handle:
1. Fit screws and nuts (6) and torque tighten in accordance with
the requirements (see Step 5).
2. Fit the complete handle on the disc connection and tighten
the screw on the handle.
NOTE!
This also applies for the Lockable Multiposition Handle. TD 403-267
Step 4
Valve with actuator:
1. Fit the actuator with the bracket so that the disc connection
enters the coupling (see 3.4 Fitting actuator/bracket/handle
on the valve (optional extras)).
2. Fit screws and nuts (6) and torque tighten in accordance with
the requirements so that the bracket is fixed to the valve (see
Step 5).
TD 403-268
Fit correctly!
See 3.4 Fitting actua-
tor/bracket/handle on the
valve (optional extras)
Step 5
Pre-use check: Check that the valve disc moves smoothly against the seal ring.
Pay special attention to the warnings!
Too l s/torque values for assembly of the valve body halves:
1” 1½” 2” 2½” 3” 4”
25 mm 38 mm 51 mm63.5 mm 76 mm 101.6 mmValve size
DN 25 DN32 DN40 DN50 DN65 DN80 DN100
5mm 5mm 5mm 6mm6mm6mm8mm
Allen Key
(0.2”) (0.2”) (0.2”) (0.24”) (0.24”) (0.24”) (0.3”)
18 Nm 18 Nm 18 Nm 20 Nm 20 Nm 20 Nm 38 NmRecomm.
Torqu e (13 lbf-ft) (13 lbf-ft) (13 lbf-ft) (15 lbf-ft) (15 lbf-ft) (15 lbf-ft) (38 lbf-ft)
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
NC = Normally closed. NO = Normally open. A/A = Air/air activated.
5.4 Dismantling of actuator
Step 1
1. Press end cap (5) into air cylinder (1).
2. Remove retaining ring (6).
Use a press or special tool (item no. 9611416791).
TD 403-099
Step 2
NC/NO actuator:
Release the pressure on end cap (5) carefully and remove the end
cap.
Pay special attention to the warning!
TD 403-100
Step 3
A/A actuator:
Remove end cap (5) by hand.
Pay special attention to the warning!
TD 403-101
Step 4
Remove piston (3) and the springs.
NOTE!
- The actuator size ø133 mm has a caged spring assembly.
- The air/air actuator has no springs.
TD 403-271
Step 5
Remove connex pin (16) and coupling (17) from rotating cylinder
stem (2).
TD 403-119
Step 6
Remove rotating cylinder (2) and the remaining internal parts from
air cylinder (1).
TD 403-120
19

5 Maintenance
Study the instructions carefully.
NC = Normally closed. NO = Normally open. A/A = Air/air activated.
Lubricate the rubber seals before fitting them. Lubricate the bearings.
Clean the piston before assembly.
5.5 Assembly of actuator
Step 1
Fit rotating cylinder (2) in air cylinder (1).
TD 403-269
Step 2
Fit coupling (17) on rotating cylinder stem (2) and fit connex pin
(16). Fit the connex pin
correctly!
TD 403-270
Step 3
Fit the springs in rotating cylinder (2) and fit piston (3) carefully.
CAUTION!
Fit the piston correctly in relation to the bearings.
NOTE!
The air/air actuator is has no springs.
TD 403-274
Fit correctly!
Step 4
A/A actuator:
1. Fit end cap (5) sufficiently into air cylinder (1) so that retaining
ring (6) can be fitted in the air cylinder.
2. Position the end cap correctly by hand.
Pay special attention to the warning! TD 403-272
Step 5
1. Fit end cap (5) in air cylinder (1) and press sufficiently down so
that retaining ring (6) can be fitted in the air cylinder.
2. Release the pressure on the end cap.
Pay special attention to the warning!
Use a press or special tool (item no. 9611416791). NC/NO actuator
TD 403-273
Step 6
Pre-use check:
1. Supply compressed air to the actuator.
2. Activate the actuator several times to ensure that it operates smoothly.
Pay special attention to the warnings!
20