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
+4579322200
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
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