Alfalaval LKDC User manual

TE91K040
First published: May 7, 2012
ESE02229-EN4 2018-10
Original manual
Instruction Manual
Alfa Laval LKDC, LKD & COR Covers

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Safety .................................................................................................... 4
1.1. Important information ............................................................................. 4
1.2. Warning signs ..................................................................................... 4
2. Introduction ............................................................................................ 5
2.1. Introduction ........................................................................................ 5
2.2. Intended use ...................................................................................... 5
3. Installation .............................................................................................. 6
3.1. Employment ....................................................................................... 6
4. Operation ............................................................................................... 7
4.1. Closing and tightening ........................................................................... 7
4.2. Opening ............................................................................................ 7
4.3. Safety regulations ................................................................................. 7
4.4. Welding ............................................................................................ 8
5. Special precautions regarding the LKD 440X320 ................................................ 9
5.1. Installation ......................................................................................... 9
6. Maintenance ........................................................................................... 10
6.1. Maintenance ....................................................................................... 10
7. General information ................................................................................... 11
7.1. Service and repair ................................................................................ 11
7.2. Warranty ........................................................................................... 11
7.3. How to contact Alfa Laval Kolding A/S ......................................................... 11
3

1 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the cover!
1.1 Important information
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 cover.
NOTE
Indicates important information to simplify or clarify procedures.
1.2 Warning signs
General warning:
4

2 Introduction
Study the instructions carefully and pay special attention to the warnings!
2.1 Introduction
The Alfa Laval manway doors and manhole covers do not come within the definition of pressure equipments of the article 1.2.1,
and are, therefore, not marked CE, ref. Guideline 1/22 of the PED Guideline approved by the WPG 29-06-2002.
These instructions are valid only for the use of Alfa Laval manway doors and manhole covers.
With the knowledge of these instructions incorrect use can be avoided.
Warning: The service personnel must be acquainted with the content of these instructions.
Incorrect use can be of danger to the user or a third party, and can cause damage to objects and/or people.
You will find the information contained in this manual simple to follow, but should you require further assistance, our Technical
Sales Support Department and worldwide net of sales offices are pleased to help you.
NOTE
The illustrations and specifications contained in this manual were effective at the date of printing. However, as continuous
improvements are our policy, we reserve the right to alter or modify any unit specification on any product without prior notice or
any obligation.
The English version of the instruction manual is the original manual. We make reservations in regard to possible mistranslations in
language versions of the instruction manual. In case of doubt, the English version of the instruction manual applies.
2.2 Intended use
The end-user should verify:
- that the tank cover is in conformity with respect to tank, vessel or container size in which it is used.
- that the construction materials (both metallic and nonmetallic) are compatibility with product, flushing media, cleaning
media, temperatures and pressure under the intended use.
5

3 Installation
Study the instructions carefully and pay special attention to the warnings!
3.1 Employment
1. The cover shall be installed in accordance with national regulations for safety and other relevant regulations and standards.
2. The item cannot work autonomously, but it is intended for installation through welding on a tank. It is the responsibility of the
contractor to respect the regulations related to the construction of said equipment.
3. On the manway door/manhole cover, loads, solicitations or vibrations of external origin should be avoided.
4. Instructions as to the positioning of the product (horizontally or vertically, above or below the liquid level of the tank) are
included in the product data sheets. Positioning the product in any position other than as shown in the catalogue may
damage the manway and cause leakages. Do not apply any loads to the manhole or cause stress by vibrations. Use only the
components (frame, lid, bolts, arms) provided by Alfa Laval. The Alfa Laval products are individually fitted. The manway
door/manhole cover is delivered complete and assembled by qualified personnel; Always use the manhole together with
the frame provided. Decoupling the frame from the manhole lid could result in improper fit. Its components (frame, cover,
eyebolt, arm) cannot be removed and separately reassembled on other similar items.
5. The manway door/manhole cover is marked on the frame. Do not remove neither alter the marking.
6. The manway door/manhole cover is individually fitted. Always use the manhole together with the frame provided. Decoupling
the frame from the manhole could result in improper fit. Do not disassemble and do not use with any other component.
6

4Operation
Study the instructions carefully and pay special attention to the warnings!
4.1 Closing and tightening
Warning:
The service personnel are responsible for the secure closing of the manway door/manhole cover.
1. Before closing it must be verified that the contact surface of the gasket is clean and without any external objects that can
damage its good condition. The state of the gasket and its seats must always be checked.
2. While closing, it must be verified that the cover suits well with the frame, and that the cover is centred with the frame without
effort or without being off-centre, and that the gasket is in its seat.
Before closing the handles it must be verified that there is a small clearance between the frame and the cover, which is a sign
that there is no metallic impediment to the closing.
Do not close the handles with levers, pipes and/or key that can damage the functionality.
NOTE
LKD model only: The static strength of pressure has to act on the gasket, and the tightening must be effected in a uniform
way (example of cross tightening).
4.2 Opening
1. Before opening the manway door/manhole cover make sure that the tank/container/equipment is not pressurized and
without heat and/or chemical and toxic vapours.
NOTE
If necessary, use protective garments (see section 4.3 Safety regulations).
2. Slowly unscrew the handles in the same way in which they have been screwed (cross way).
3. Once opened, the cover must be positioned so damage to the gasket is avoided.
4.3 Safety regulations
Warning: All operations on the manway doors/manhole covers or operations connected herewith must be conducted by
qualified personnel, trained on the regulations related to the functioning of the tanks and more precisely to the
pressure to which they are subject.
Warning: When opening make certain that the components of the closing systems (handle, bush, washer etc.) are screwed
in such way that the components do not fall out.
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4Operation
Study the instructions carefully and pay special attention to the warnings!
4.4 Welding
1. The weld between frame of the manway door/manhole cover and the tank must be preceded by an accurate preparation
of the edges to be welded, and by a perfect adaptation.
2. Welding work, perforation, folding, cutting or similar must not be performed on the manway door/manhole cover, if such
actions are not absolutely necessary for the installation of the manway door/manhole cover.
3. Avoid an excessive stretching of the material.
4. Before welding the frame of the manway door/manhole cover onto the tank, carefully prepare the surfaces and edges to be
welded cleaning them with a degreasing agent and dry with a clean cloth. Carefully position the manway door against the
frame to ensure cohesion.
5. During welding, close the cover on the frame using a spacer in place of the gasket in order to reduce the expansion of the
frame in respect of the cover as much as possible, to maintain the form and the original dimensions of the cover and to
assure a perfect joining with the cover itself.
6. To protect the gasket remove the gasket during the welding phase.
7. After welding always control that the sealing is in full contact with the sealing surface.
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5 Special precautions regarding the LKD 440X320
Study the instructions carefully and pay special attention to the warnings!
5.1 Installation
Oval Cover Type LKD 400 x 320
In order to obtain a perfect seal and a good function of our manhole cover it is essential that the welding of the casing is carried
out carefully and correctly. If the cover is fitted on a vertical tank wall, the hinge of the casing must always be placed on the left
hand side. For thin-gauged containers, i.e. sheet thickness less than 2.5 mm, welding is easier, if the hole is marked in such a
way that a 10 mm edge can be burred up as sharply as possibly.
When the hole is cut and the edge burred up, if applicable,
the frame is inserted, and tack-welding is now carried out on
points placed opposite each other all the way round, in the
sequence shown in figure 1. 4200-0000
The frame may now be fully welded on both sides. A control
should be made by removing the rubber seal, and cover and
frame should be assembled loosely to ensure that they fully
contact each other over the whole surface.
Any stresses are removed by hammering the sheet around
the casing.
3
7
2
6
4
8
1
5
4200-0001
Figure 1. Installation of LKD
9

6 Maintenance
Study the instructions carefully and pay special attention to the warnings!
6.1 Maintenance
1. Periodically check the condition of the gasket, wash it and carefully dry it. Replace if necessary.
2. The process of control and periodic washing is also valid for the seat of the gasket on the cover.
3. Periodically check the state of the closing systems, eyebolts and handles. Replace if necessary.
NOTE
Special Maintenance only valid for the LDK and O-series with SS wing handle:
1. After 24 months of operation, check cross arm. Verify that the cross arm has not been subject to excessive stress due
to overstraining of the SS-wing handle. (Applying excessive force on the SS-wing handle during tightening will deform
the cross arm over time).
1
2
4200-0003
Position 1: SS wing handle
Position 2: Cross arm
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