Alfalaval ALP 15-85 User manual

Marine & Diesel Equipment
Oil Feed Pumps ALP 15-85
X027351A
Product No.
Printed
Book No.
Jan 2020
9006009-02 V13
Component
Description

Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: [phone]
Telefax: [phone]
©AlfaLavalTumbaAB01-2020
Original instruction
This publication or any part there of may not
be reproduced or transmitted by any process
or means without prior written permission of
Alfa Laval Tumba AB.

Contents
1 EC Declaration of Conformity 7
2 Warning signs in text 9
2.1 Warning signs 9
3 Function Description 11
3.1 Application 11
3.1.1 Safety information 11
3.2 Design 12
3.2.1 Mechanical seal 12
3.2.2 Direction of Rotation 13
3.2.3 Pressure relief valve 13
3.3 Parts 14
4 Fault Finding 19
4.1 Possible faults 19
4.2 Troubleshooting 19
5 Maintenance 23
5.1 Safety instructions on maintenance and
repairs 23
5.2 Required maintenance 24
5.3 Mechanical seal 24
5.4 Ball bearing 24
5.5 Cleaning the leakage vent hole 25
5.6 Replacing the elastomer coupling 26
5.7 Replacing the mechanical seal and ball
bearing 29
5.7.1 Dismantling 29
5.7.2 Assembly 31
6 Technical Data 33
6.1 Operating limits 33
6.2 Required Net Positive Suction Height
(NPSH) values 33
3

6.3 Weights 34
6.4 Dimensions 35
6.4.1 Dimension drawing of ALP pump and pump unit 36
6.5 Capacity tables 37
6.5.1 Capacity at 50 Hz, delta = 4 bar 37
6.5.2 Capacity at 60 Hz, delta = 4 bar 38
6.5.3 Noise levels 39
6.5.4 Labelling 39
7 Installation 41
7.1 Installing the pump 41
7.2 Protect the pump against contamination 42
7.3 Piping 43
7.4 Strainer 43
7.5 Gauges 44
7.6 Commissioning 44
7.6.1 Cleaning the pipe system 44
7.6.2 Filling the pump 44
7.6.3 Checking the direction of rotation 46
7.6.4 Taking the pump out of operation 47
7.6.5 Recommissioning the pump 48
8 Transportation, storage and
disposal 49
8.1 Unpacking and checking the state of
delivery 49
8.2 Lifting the pump/pump unit 50
8.2.1 Pump 51
8.2.2 Pump unit 51
8.3 Storage 51
8.3.1 Preservation 52
8.3.2 Preserving the internal surfaces of the pump 52
8.3.3 Preserving the external surfaces of the pump 52
8.3.4 Removing the preservation 53
8.4 Disposing of the pump 53
9 Spare parts 55
9.1 Spare part kits 55
9.1.1 Tightening torques 59
9.1.2 Required tools for maintenance work 59
4

!
Study instruction manuals and observe the
warnings before installation, operation,
service and maintenance.
Not following the instructions can result
in serious accidents.
In order to make the information clear only
foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.
5

!

1 EC Declaration of Conformity
X027551A
The designating company
Alfa Laval Kolding A/S
Company name
Albuen 31, DK–6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declares that
Denomination: Three-Screw Pump
Type: ALP
Date: 2019-01-16
Is in conformity with
- Machinery Directive 2006/42/EC
and furthermore declares that if motorised the following applicable directives have been used
- Directive 2014/35/EU on low voltage
- EMC Directive 2014/30/EU
The technical construction file for this machinery has been drawn up. The signer of this declaration
is authorized to compile the technical file.
Manager, Product Center Fluid Handling Bjarne Søndergaard
Title Name
Alfa Laval Kolding A/S X027541A
Company Signature
7

1 EC Declaration of Conformity

2 Warning signs in text
2.1 Warning signs
Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.
D
!ANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
!WARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
!CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
NOTE
NOTE indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
9

2 Warning signs in text

3 Function Description
The operating instructions form part of the pump
or of the pump unit and must be kept for future
reference. Furthermore please observe the
associated documents.
3.1 Application
Use the pump solely for transporting fuel or
lubricating oils that are chemically neutral and
that contain no gas or solid components.
Use the pump only within the performance
limitations specified on the machine plate and
in the "Technical data" section. In the case of
operating data that does not agree with the
specifications on the machine plate, please
contact the manufacturer.
The pump is specifically configured for the
operating pressure stated in chapter 5.
3.1.1 Safety information
The following general safety instructions must
be observed:
• No liability is accepted for damage arising
through non-observance of the operating
instructions.
- Read the operating instructions carefully
and observe them.
- The operator-owner is responsible for the
observance of the operating instructions.
-In
stallation, removal and installation work
may only be carried out by authorised
personnel.
• In order for the warranty to remain valid,
corrective maintenance carried out during
the warranty period requires the express
permission of the manufacturer.
• Observe the general regulations for the
prevention of accidents as well as the local
safety and operating instructions.
11

3 Function Description
• Observe the valid national and international
standards and specifications of the
installation location.
• In case of systems with an increased
potential of danger to humans and/or
machines the failure of a pump may not
lead to injuries or damage to property.
- Always equip systems with an increased
potential of danger with alarm equipment.
- Maintain and check the protective/alarm
equipment regularly.
• The pumped liquids can be dangerous
(e.g. hot, dangerous to health, poisonous,
combustible). Observe the safety
regulations for handling dangerous
materials.
• Pumped liquid can be subject to high
pressure and can cause damage and/or
personal injury should leaks occur.
3.2 Design
Screw pumps are rotating displacement pumps
whose displacement effect results from the
meshing of three rotating screws and the
enclosing housing. The radial support of the
screws is effected by the sliding contact in
the housing which requires lubrication by the
pumped liquid. Screw pumps are therefore not
suitable for dry running and can only be used up
to specific pressure and viscosity limits. Due to
the narrow tolerances, pumping of suspended
solids is not possible. Axial support of the
main screw is carried out by a deep-groove
ball bearing. An internal pressure relief valve
protects against excessive pressure that could
cause housing parts to burst.
3.2.1 Mechanical seal
The functionality of a mechanical seal is based
on the formation of a hydrodynamic film between
rotary seal ring and stationary seal ring of a
mechanical seal. The formation of this film
avoids solid body friction between both parts, the
stability of the film therefore is essential for the
functionality of the mechanical seal. However,
the formation of a fluid film also means that
12

3 Function Description
the differential pressure on the seal will always
move some fluid through the gap which is filled
by the film. Therefore a properly designed
mechanical seal will always show a certain
amount of leakage. The amount of leakage is
depending on various factors, dominated by
size, rotation speed and differential pressure. In
any case, a leakage of less than 10 drops per
hour (approx. 0.5 cm3/h) is considered to be
normal and gives no reason for a replacement
of the seal.The integrated leakage vent hole
allows draining of this leakage. The drainage
through these hole has to be kept free, see 5.5
Cleaning the leakage vent hole on page 25.
Dry running must be avoided at all costs, as the
seal will overheat and be destroyed in a matter
of minutes.
3.2.2 Direction of Rotation
Standard direction of rotation: clockwise, viewed
from the drive; marked on the housing by two
arrows, see 7.6.3 Checking the direction of
rotation on page 46.Flowdirection:markedon
the housing by two arrows, see 7.6.3 Checking
the direction of rotation on page 46.
3.2.3 Pressure relief valve
The integrated pressure relief valve prevents
very high pressures which can result in housing
parts bursting. The valve is purely there as
a safety element and should not be used
for control or regulation such as maintaining
pressure. Circulation through the pressure relief
valve for too long heats the pump to excess.
This reduces viscosity and can ultimately lead
to pump failure. Setting: The valve spring is
pretensioned to an opening pressure of 6 bar
±10 % for separator applications, or delta 10 bar
±10 % for fuel conditioning applications.
13

3 Function Description
3.3 Parts
1 Pressure relief valve 10 Mechanical seal
2Screwplug 11 Pump
3 Idle screw 12 adapter housing
4 End cover 13 Motor
5Sealingsleeve 14 adapter housing foot
6 Ball bearing 15 Motor-side coupling half
7Mainscrew 16 Coupling intermediate ring
8 Pump housing 17 Pump-side coupling half
9 Leakage vent hole
14

3 Function Description
X027101A
Fig. 1.Structure of ALP pump
X027111A
Fig. 2.Structure of ALP pump with elastomer coupling and motor
15

3 Function Description
Parts table
Pos. no. Denomination Pos. no. Denomination
001 Pump 472 Circlip
039*** Distance sleeve 501 Spring
043 Sealing sleeve 525 Coupling intermediate ring
052 Coupling 526 Pump bracket foot
056(*) Supporting ring 529 Motor
058 L-ring 661** Screw set
070 End cover 739.1 O-ring
131 Pump housing 817 Ball bearing
165.1 Screw plug 866 Feather key
165.2 Screw plug 894 Hexagon nut
180 Pump bracket 914.1 Socket screw
222 Flat gasket 914.2 Socket screw
305 Valve body 914.3 Socket screw
457 Mechanical seal 914.4 Socket screw
471 Circlip
*Only for sizes 15 – 20.
** In case of wear of the screw set it is recommended to replace the pump.
*** Only for sizes 55 – 85 (motor sizes IEC 90 – 112).
16

3 Function Description
070
914.1 165.1
222
131
165.2
305
501 859
866
661
457 739.1
043
817
056
471
472
056*
8
X027151A
Fig. 1.ALP 15–85
914.2
001
525
894 526
180
914.4
529 914.3
052
039***
X027161B
Fig. 2.Completion elastomer coupling ALP 15–85
17

3 Function Description

4 Fault Finding
4.1 Possible faults
Faults can have different causes. The following
tables list the symptoms of a fault, the possible
causes and measures for elimination.
Fault Cause/Remedy
No pump suction 1, 2, 3, 4, 5, 6, 7, 8, 30
Delivery rate too low 2, 3, 4, 9, 10, 11, 12, 13, 14, 15, 16
Pump runs noisily 2, 3, 4, 6, 10, 12, 14, 18, 19, 20, 21
Motor overload 9, 10, 13, 21, 22, 25
Uneven delivery rate 2, 3, 4, 6, 10, 12, 14, 15
Leaking shaft seal 17, 23, 24, 25
Pump has seized up 26, 27, 28, 29
4.2 Troubleshooting
No. Cause Remedy
1Pumpsuctionpipeclosed Check shut-off devices in the suction pipe and
open them, if necessary.
2Suction valve or pipe obstructed Check the suction valve and pipe for clear passage.
3Suction pipe or shaft seal leaks Check suction pipe or shaft seal for leaks. Pay
particular attention to leakage at valves and
connection points. If necessary, replace parts.
Reinstall the pump at lower suctiion head level.
-or-
Reduce pipe length
-or-
Increase pipe diameter
-or-
Heat the liquid to reduce viscosity
-or-
4Suction head too high
Check that the strainer is not clogged, see 7.4
Strainer on page 43.
5Level of liquid in the intake container
too low Top up the pumped liquid.
6Dirty filter/strainer Clean the filter/strainer.
7Pump suction capacity reduced by
inadequate wetting Fill pump with liquid.
19

4 Fault Finding
No. Cause Remedy
8Incorrect pump direction of rotation Carry out the electrical connection so that the
direction of pump rotation matches that of the
arrow on the flange cover, see 7.6.3 Checking the
direction of rotation on page 46
9Differential pressure too high Check the system and reduce the differential
pressure.
Increase the temperature of the liquid
-or-
10 Viscosity of the pumped liquid too
high
Reduce the rotation speed.
Decrease the temperature of the liquid
11 Viscosity of the pumped liquid too
low -or-
Increase the rotation speed.
Test the pipe system for ingress of air and replace
parts if necessary.
Reduce the suction head
-or-
12 Airlock or gas in the liquid
Increase the inlet pressure.
Ensure that the motor voltage and frequency match
the operating voltage.
13 Motor running at wrong voltage or
frequency
Compare the speed of the motor with the pump
communication plate. If the data does not match,
adjust the speed of the motor.
14 Pressure relief valve opens during
normal operation Reduce operating pressure.
15 Pressure relief valve leaks Clean the pressure relief valve and reseat if
necessary.
Check screw set and housing and replace the
pump if necessary.
16 Advanced wear of rotating pump
components
Replace the seal and check the pumped liquid for
abrasive content.
17 Advanced wear of sealing surfaces Support the weight of the pipe system.
18 Pump distorted Loosen pipework connections and mount
stress-free, see 7.3 Piping on page 43.
Provide a flexible bearing arrangement for the
pump unit
-or-
19 Resonance in the system
Make the connections with hoses.
Set the flow speed in the suction pipe so that it
does not exceed 1 m/s.
20 Speed of flow in suction or pressure
pipe too high
Set the flow speed in the pressure pipe so that it
does not exceed 3 m/s.
21 Ball bearing damaged Replace the ball bearing, see 5.7 Replacing the
mechanical seal and ball bearing on page 29.
22 Lack of lubrication or foreign bodies
have caused superficial damage to
rotating pump components
Check the screw set and the housing. If necessary
replace the pump with free shaft end.
23 Dry running has damaged the shaft
seal
Replace the shaft seal, see 5.7 Replacing the
mechanical seal and ball bearing on page 29.
When starting up the pump, pay attention to
venting.
20