Alfa level LKH-5 User manual

Instruction Manual
LKH Centrifugal Pump
ESE00698-EN13 2009-12
Original manual

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 ....................................................................... 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Safety precautions ................................................................................ 7
3. Installation .............................................................................................. 8
3.1. Unpacking/Delivery ............................................................................... 8
3.2. Installation ......................................................................................... 9
3.3. Pre-use check - Pump without/with impeller screw ........................................... 10
4. Operation ............................................................................................... 11
4.1. Operation/Control ................................................................................. 11
4.2. Fault finding ....................................................................................... 13
4.3. Recommended cleaning ......................................................................... 14
5. Maintenance ........................................................................................... 15
5.1. General maintenance ............................................................................. 15
5.2. Dismantling of pump/shaft seals ................................................................ 17
5.3. Assembly of pump/single shaft seal ............................................................ 19
5.4. Assembly of pump/flushed shaft seal ........................................................... 21
5.5. Assembly of pump/double mechanical shaft seal ............................................. 23
5.6. Adjustment of shaft (LKH-5) ..................................................................... 25
5.7. Adjustment of shaft (LKH-10 to -90) ............................................................ 27
5.8. Cleaning Procedure ............................................................................... 29
6. Technical data ......................................................................................... 30
6.1. Technical data ..................................................................................... 30
6.2. Relubrication Intervals ............................................................................ 31
6.3. Addendum ......................................................................................... 32
7. Parts list and Service Kits ........................................................................... 33
7.1. LKH-5 Sanitary Version .......................................................................... 33
7.2. LKH-10, -15, -20, -25, -35, -40, -50, -60 Sanitary Version .................................. 34
7.3. LKH-70 - 90 Sanitary Version ................................................................... 35
7.4. LKH-5 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal .............. 36
7.5. LKH-10 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 38
7.6. LKH-15 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 40
7.7. LKH-20 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 42
7.8. LKH-25 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 44
7.9. LKH-35 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 46
7.10.LKH-40 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 48
7.11.LKH-45 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 50
7.12.LKH-50 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 52
7.13.LKH-60 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 54
7.14.LKH 5-60 Centrifugal Pumps, Shaft Seals ..................................................... 56
7.15.LKH-70 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 58
7.16.LKH-75 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 60
7.17.LKH-80 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 62
7.18.LKH-85 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 64
3

Tab le of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
7.19.LKH-90 Centrifugal Pump Single, Flushed and Double Mechanical Shaft Seal ............ 66
7.20.LKH-70, LKH-75, LKH-80, LKH-85 and LKH-90 Centrifugal Pump, Shaft Seal ........... 68
4

1 EC Declaration of Conformity
The designated company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Pump LKH
Denomination Type Year
is in conformity with the following directives with amendments:
- Low Voltage Directive 2006/95/EC
- EMC Directive 2004/108/EC
- Machinery Directive 2006/42/EC
The technical construction file is retained at the above address
Manager, Product Center Fluid Handling Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
5

2Safety
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 pump!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
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.
6

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 pump are avoided.
2.3 Safety precautions
Installation:
Always
read the technical data thoroughly. (See chapter 6 Technical data)
Always
use a lifting crane when handling the pump.
Pump without impeller screw:
Always
remove the impeller before checking the direction of rotation.
Never
start the pump if the impeller is fitted and the pump casing is removed.
Pump with Impeller screw:
Never
startinthewrongdirectionofrotationwithliquidinthepump.
Always
have the pump electrically connected by authorized personnel.
Always
have the pump electrically connected by authorized personnel. (See the motor instruction)
Operation:
Always
read the technical data thoroughly. (See chapter 6 Technical data)
Never
run the pump when partially installed or not completely assembled
Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations
Never
touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never
run the pump with both the suction side and the pressure side blocked.
Always
handle lye and acid with great care.
Maintenance:
Always
read the technical data thoroughly. (See chapter 6 Technical data)
Never
service the pump when it is hot.
The pump and the pipelines must n
never
be pressurised when the pump is serviced.
Motors with grease nipples:
Remember lubrication according to information plate/label on the motor.
Always
disconnect the power supply when servicing the pump.
Transportation:
Transportation of the pump or the pump unit:
Never
lift or elevate in any way other than described in this manual
Always
drain the pump head and accessories of any liquid
Always
ensure that no leakage of lubricants can occur
Always
transport the pump in it’s upright position
Always
ensure that the unit is securely fixed during transportation
Always
use original packaging or similar during transportation
7

3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The large pump sizes are very heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
3.1 Unpacking/Delivery
Step 1
Always use a lifting crane when handling the pump (see technical
data).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
Step 2
Remove possible packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
TD 200-120_1
Remove
packing
materials!
Caution!
Step 3
Inspect the pump for visible transport damages.
Inspection!
TD 200-120_1
Step 4
Alwaysremovetheshroud,iffitted,beforeliftingthepump.
Remove the shroud before lifting!
Step 5
ONLY LKH-85 and LKH-90
Do N
NOT
use eyebolt in casing to lift the pump. The eyebolt is
only for casing removal.
8

3 Installation
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 3.3 Pre-use check - Pump without/with impeller screw.
The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
3.2 Installation
Step 1
Always
read the technical data thoroughly.
(See chaper 6 Technical data)
Always
use a lifting crane when handling the pump.
(See chaper 6 Technical data)
Always
have the pump electrically connected by
authorized personnel.
(see the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
Step 2
Ensure at least 0.5 m (1.6 ft) clearance around the pump.
Step 3
Check that the flow direction is correct.
O: Outlet
I: Inlet Correct!
S
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
Few bends
Correct!
S
Step 5
Avoid stressing the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
9

3 Installation
Study the instructions carefully and pay special attention to the warnings!
LKH-5 to -60 is without impeller screw as standard but can be supplied with one.
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check - Pump without/with impeller screw
Step 1
Always
remove the impeller before checking the direction of
rotation.
Never
start the pump if the impeller is fitted and the pump casing
is removed.
1.
A. LKH-5: Remove screws (56), spring washers (56a), clamps
(55+55a) and pump casing (29).
B. LKH-10 to -90: Remove cap nuts (24), washers (24a) and
pump casing (29).
2. Remove impeller (27) (see also instruction in section 5.3
Assembly of pump/single shaft seal).
S
Step 2
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the stub shaft (7) is
anticlockwise as viewed from the inlet side.
See the indication label!
Correct!
Stub shaft
Step 3
Fit and tighten impeller (27).
S
Step 4
1. Fit pump casing (29).
2.
A. LKH-5: Fit clamps (55+55a), spring washers (56a) and
tighten screws (56)
B. LKH-10 to -90: Fit washers (24a) and tighten cap nuts (24),
according to torque values in chapter 6.3 Addendum
Step 1
Pump with impeller screw
Never
start in the wrong direction of rotation with liquid in the
pump.
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the motor fan is
clockwise as viewed from the rear end of the motor.
See the indication label!
Correct
View from rear end of
motor
10

4Operation
Study the instructions carefully and pay special attention to the warnings!
The pump is fitted with a warning label indicating correct throttling
4.1 Operation/Control
Step 1
Always
read the technical data thoroughly.
See chapter 6 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect
operation/control.
Step 2
Never
touch the pump or the pipelines when pumping hot liquids
or when sterilising.
Burning danger!
Step 3
Never
run the pump with both the suction side and the pressure
side blocked.
Explosion danger!
S
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never
throttle the inlet side.
Do not run dry! See the warning
label!
Correct!
TD 200-129_1
Wrong
11

4Operation
Study the instructions carefully and pay special attention to the warnings!
The pump is fitted with a warning label indicating correct throttling
Step 5
Flushed shaft seal:
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
3. Observe the steam data.
For LKH-85: connect inlet/outlet of the flushing liquid directly
on the flushing housing.
O: Free outlet
I: Inlet
Correct!
R 1/8” (BSP)
O
I
Tmax = 100ºC
Pmax = 1 bar
TD 200-130_1
S
Step 6
Control:
Reduce the capacity and the power consumption by means of:
- Throttling the pressure side of the pump.
- Reducing the impeller diameter.
- Reducing the speed of the motor.
Throttling!
12

4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Fault finding
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See section 5.1 General maintenance
Problem Cause/result Remedy
Overloaded motor - Pumping of viscous liquids - Larger motor or smaller impeller
- Pumping of liquids with high density
- Low outlet pressure (counter pressure) - Higher counter pressure (throttling)
- Lamination of precipitates from the
liquid
- Frequent cleaning
Cavitation:
- Damage - Low inlet pressure - Increase the inlet pressure
- Pressure reduction (sometimes to
zero)
- High liquid temperature - Reduce the liquid temperature
- Increasing of the noise level - Reduce the pressure drop before the
pump
- Reduce speed
Leaking shaft seal - Dry run (See 4.1 Operation/Control) Replace:
All wearing parts (See 5.1 General
maintenance)
- Incorrect rubber grade If necessary:
- Change rubber grade
- Abrasive particles in the liquid - Select stationary and rotating seal ring
in Silicon Carbide/Silicon Carbide
Leaking seals Incorrect rubber grade Replace with seals of a different rubber
grade
13

4Operation
The pump 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 pump or the pipelines when sterilizing.
Burning danger!
Step 3
Examples of cleaning agents:
Use clean water, free from
chlorides.
1. 1% by weight NaOH at 70°C (158°F).
1kg(2.2lb) +100 l (26.4 gal) = Cleaning agent.
NaOH water
2.2 l (0.6 gal) +100 l (26.4 gal) = Cleaning agent.
33%NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100 l (26.4 gal) = Cleaning agent.
53% HNO3water
Step 4
1. Avoid excessive concentration of the cleaning agent
Dose gradually!
2. Adjust the cleaning flow to the process
Sterilization of milk/viscous liquids
Increase the cleaning flow!
Step 5
Always
rinse well with clean water after using a cleaning agent.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current rules/directives.
Always rinse!
Water Cleaning agent
14

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
5.1 General maintenance
Step 1
Always
read the technical data thoroughly.
(See chaper 6 Technical data)
Always
disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored/discharged in accordance with current
rules/directives.
Step 2
Never
service the pump when it is hot.
Burning danger!
Step 3
Never
service the pump with pump and pipelines under pressure.
CAUTION
Fit the electrical connections correctly if they have been removed
from the motor during service.
(see 3.3 Pre-use check - Pump without/with impeller screw)
CAUTION
Pay special attention to the warnings!
Atmospherie pressure
required!
Step 4
Recommended spare parts:
Service kits (see chapter 7 Parts list and Service Kits).
Order Service Kits from Service kits list (see chapter 7 Parts list
and Service Kits).
Ordering spare parts
Contact the Sales Department.
15

5 Maintenance
Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings!
Always keep spare shaft seals and rubber seals in stock.
See separate motor instructions.
Check the pump for smooth operation after service.
Shaft seal Rubber seals
Motor bearings
Preventive maintenance R
Replace after 12 months:
(one-shift) Complete shaft seal
Replace when replacing the
shaft seal
Maintenance after leakage
(leakage normally starts slowly)
Replace at the end of the
day:
Complete shaft seal
Replace when replacing the
shaft seal
Planned maintenance - Regular inspection for
leakage and smooth
operation
- Keep a record of the pump
- Use the statistics for
planning of inspections
Replace after leakage:
Complete shaft seal
Replace when replacing the
shaft seal
Yearly inspection is
recommended
- Replace complete bearing
if worn
- Ensure that the bearing is
axially locked (See motor
instructions)
Lubrication B
Before fitting
Lubricate the O-rings with
silicone grease or silicone oil
Before fitting
Silicone grease or silicone oil
See section 6.2 Relubrication
Intervals
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service. (See 3.3 Pre-use check -
Pump without/with impeller screw).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
5.2 Dismantling of pump/shaft seals
Step 1
1.
A. LKH-5: Remove screws (56), spring washers (56a), clamps
(55+55a) and pump casing (29).
B. LKH-10 to 90: Unscrew cap nuts (24) and remove washers
(24a) and pump casing (29).
LKH-85 and LKH-90
S
Step 2
Flushed / Double Mechanical shaft seal:
Unscrew tubes (42) using a spanner.
S
Step 3
Remove screw (23) and safety guard (22).
Step 4
1. Remove impeller screw (36), if fitted.
2. Remove impeller (27). If necessary, loosen the impeller by
knocking gently on the impeller vanes.
3. Remove the O-ring (38) from the impeller, if fitted.
Counterhold
with a
screwdriver!
If necessary!
S
Step 5
1. Pull off the O-ring (26) from back plate (25).
2. Unscrew nuts (20) and remove washers (21) and the back plate.
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
Step 6
1. Remove the stationary seal ring (11).
2. Remove the O-ring (12) from back plate (25).
Use the tool
supplied
TD 200-462
Left hand
thread!
S
Step 7
Flushed shaft seal:
1. Remove screws (41) and seal housing (40).
2. Pull out lip seal (43) from the seal housing.
TD 200-390_1
Step 8
Double mechanical shaft seal:
1. Remove screws (41) and seal housing (40a).
2. Remove rotating seal rings (14) and drive ring (52) from spring
(13).
3. Remove O-rings (15) from rotating seal rings (14).
4. LKH-70 to 90: Remove cups (54) from rotating seal rings.
S
Step 9
Double mechanical shaft seal:
1. Remove stationary seal ring (51) from seal housing (40a).
2. Remove O-ring (50) from stationary seal ring (51).
3. Remove O-ring (44) from seal housing (40a).
TD 200-391_1
Step 10
1. Remove the complete shaft seal from stub shaft (7).
2. Remove spring (13) and rotating seal ring (14) from the drive
ring (10).
TD 234-021_1
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
5.3 Assembly of pump/single shaft seal
Step 1
1. Remove spring (13).
NOTE!
Make sure that O-ring (15) has max. clearance from the sealing
surface.
S
Step 2
1. Refit spring (13) on rotating seal ring (14).
2. Fit the spring and the rotating seal ring on drive ring (10).
CAUTION
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring. TD 200-393_1
S
Step 3
Fit the complete shaft seal on stub shaft (7).
NOTE!
Make sure that connex pin (8) on the stub shaft enters the notch in
drive ring (10).
Step 4
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
2. Screw the stationary seal ring into back plate (25).
CAUTION
Only tighten by hand to avoid deforming the stationary seal ring.
(Max 7Nm/5 lbf-ft)
Use the tool
supplied
TD 200-462
Left hand
thread!
S
Step 5
1. Clean the sealing surfaces with contact cleaner before fitting
back plate (25).
2. Carefully guide the back plate onto adaptor (16).
3. Fit washers (21) and nuts (20).
TD 234-009_1
Step 6
Lubricate O-ring (26) and slide it onto back plate (25).
TD 234-026_1
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
Step 7
1. Lubricate O-ring (38) and fit it in impeller (37), if impeller screw
is used.
2. Lubricate impeller hub with silicone grease or oil.
3. Screw the impeller onto stub shaft (7).
4. Fit impeller screw (39) and tighten, if used.
Torque - 5-60 = 20 Nm (7.4 lbf-ft)
Torque - 70-90 = 50 Nm (37 lbf-ft)
S
Step 8
Fit safety guards(22)andscrew(23)andtighten.
Step 9
1.
A. LKH-5: Fit pump casing (29), clamps (55+55a), spring
washers (56a) and screws (56).
B. LKH-10 to-90: Fit pump casing (29), washers (24a) and
cap nuts (24).
2. Adjust pump casing to the right position.
3.
A. LKH-5: Tighten nuts (20) for back plate (25) and tighten
screws (56).
B. LKH-10 to -90: Tighten nuts (20) for back plate (25) and
tighten cap nuts (24), according to torque values in chapter
6.3 Addendum.
LKH-85 and LKH-90
20