Alfalaval DuraCirc Range User manual

Alfa Laval DuraCirc® Range
Circumferential Piston Pump
BRITISH ENGLISH
3206-0000
Lit. Code 200002348-1-EN-GB
Manual No. 100003046 Instruction Manual

Published by
Alfa Laval Kolding A/S
Albuen 31
DK-6000 Kolding, Denmark
[phone]
The original instructions are in English
© Alfa Laval Corporate AB 2021-05
This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval Corporate AB. No part of this document may be copied, re-produced or
transmitted in any form or by any means, or for any purpose, without Alfa Laval Corporate AB’s prior express written permission. Information and services provided in this document are
made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose. All rights
are reserved.

Contents
1 EU Declaration of Conformity.......................................................................... 5
2 General information................................................................................................ 7
2.1 General information...................................................................................................7
3 Safety............................................................................................................................... 9
3.1 Important information.................................................................................................9
3.2 Warning signs..........................................................................................................10
3.3 Safety precautions...................................................................................................11
4 Installation................................................................................................................... 13
4.1 Unpacking, handling and storage............................................................................13
4.2 Recycling information.............................................................................................. 14
4.3 System design, installation and operation...............................................................15
4.4 Flushing seal arrangement and pre-start up checks............................................... 21
5 Maintenance.............................................................................................................. 23
5.1 Cleaning in place (CIP)............................................................................................23
5.2 Maintenance schedule.............................................................................................25
5.3 Dismantling..............................................................................................................27
5.4 Assembly.................................................................................................................33
5.5 Primary seals removal and fitting............................................................................ 47
5.6 Heating/Cooling devices..........................................................................................57
5.7 Troubleshooting.......................................................................................................59
6 Technical data...........................................................................................................61
6.1 Technical data..........................................................................................................61
6.2 Pumphead Clearance information...........................................................................65
7 Parts list........................................................................................................................ 67
7.1 DuraCirc Pump Range............................................................................................ 67

1 EU Declaration of Conformity
The Designation Company
Alfa Laval Eastbourne, Alfa Laval Ltd
Company Name
Birch Road, Eastbourne, East Sussex BN23 6PQ
Address
[phone]
Phone No
hereby declare that
Pump
Designation
DURACIRC 32;33;34;42;43;52;53;54;62;63;72;73;74
Type
From serial number E10.000 to E1.000.000
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2021–03–31
Place Date Signature
200002348-1-EN-GB 5
EN

UK Declaration of Conformity
The Designation Company
Alfa Laval Eastbourne, Alfa Laval Ltd
Company Name
Birch Road, Eastbourne, East Sussex BN23 6PQ
Address
[phone]
Phone No
hereby declare that
Pump
Designation
DURACIRC 32;33;34;42;43;52;53;54;62;63;72;73;74
Type
From serial number E10.000 to E1.000.000
is in conformity with the following directive with amendments:
- Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597)
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pump, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding 2021–03–31
Place Date Signature
200002348-1-EN-GB6
1 EU Declaration of ConformityEN

2 General information
2.1 General information
The DuraCirc pump supplied is a positive displacement circumferential piston pump, which may be
supplied with or without a drive unit. The drawing shown indicates main components of the pump unit.
The DuraCirc range has a universal gearbox design which enables the flexibility of mounting pumps
with the inlet and outlet ports in either a vertical or horizontal plane. The port orientation, vertical or
horizontal, may be changed by moving one of two available bolt-on feet on the gearbox. Port
orientation should be specified when ordering, but the alternative foot design allows pumps that are
already installed being changed should the need arise.
Drawing shows only mounted unit
3206-0001
D
C
G
B
A
F
E
H
A Rotorcase cover
B Rotorcase
C Ports
D Gearbox
E Drive unit
F Coupling guard (encloses coupling)
G Product seal area (inside rotorcase)
H Baseplate fixing holes
Pump duty conditions
The pump should only be used for the duty for which it has been specified. The operating pressure,
speed and temperature limits have been selected at the time of order and MUST NOT be exceeded.
These details are stated on the original order documentation and if not available may be obtained
from your supplier quoting pump model and serial number.
200002348-1-EN-GB 7
EN

Noise levels
Under certain operating conditions pumps and/or drives and/or the systems within which they are
installed can produce sound pressure levels in excess of 80dB[A]. It recommended that the noise
level is measured during commissioning, running on normal operating conditions and appropriate
personal protective equipment used where necessary.
Vibration Limits
Bare shaft pump units have been tested and found to be within the limits published under ISO
10816-7 Category 2 under normal operation conditions. Actual vibration of mounted units can be
effected by numerous external factors such as mounting method, foundation, alignment, speed and
duty point. As such, we recommend the maximum operating limit of 8.5 mm/s RMS with a trip limit of
10.6 mm/s RMS as per ISO 10816-7 Cat. 2 is observed in any monitoring equipment if used.
200002348-1-EN-GB8
2 General informationEN

3 Safety
3.1 Important information
Always read the manual before using the pump!
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 pump.
NOTE
Indicates important information to simplify or clarify procedures.
This instruction manual is designed to provide the user with the information to perform tasks safely for
all phases in the life time of the product supplied.
The user shall always read the safety section first. Hereafter the user can skip to the relevant section
for the task to be carried out or for the information needed.
This is the complete manual for the supplied product.
Skills for personal:
Operators:
The operators shall read and understand the instruction manual for the supplied product
Maintenance personnel:
The maintenance personnel shall read and understand the instruction manual.
The maintenance personnel or technicians shall be skilled within the field required to carry out the
maintenance work.
Trainees:
Trainees can perform tasks under the supervision of an experienced employee.
People in general:
The public shall not have access to the supplied product.
How to contact Alfa Laval
Contact details for all countries are continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
200002348-1-EN-GB 9
EN

3.2 Warning signs
!
General warning
Dangerous electrical voltage
Caustic agents
Hot Surfaces
200002348-1-EN-GB10
3 SafetyEN

3.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See Section 6 Technical data)
Never start in the wrong direction of rotation with liquid in the pump.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
!
Always have the drive electrically connected by authorized personnel. (see the motor instructions
supplied with the drive unit.)
Alfa Laval recommends the supply disconnecting device shall be in accordance with
EN60204-1.
Operation:
Always read the technical data thoroughly. (See Section 6 Technical data)
Never stand on the pump or pipelines.
Never run the pump with either or both suction side and pressure side blocked.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
Never run the pump unless fully assembled, i.e. pump head must not be removed from gearcase.
Always ensure any guards are securely in place and in good condition.
!
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
In certain operating conditions the external surface of the pump and/or ancillary equipment may
exceed 80oC / 176o F. As such users should avoid touching the pump and/or ancillary equipment
during operation taking precautions if it is unavoidable to do so.
Always handle toxic and acidic liquids in accordance with the manufacturer’s instructions and
recommendations.
Maintenance:
Always read the technical data thoroughly. (See Section 6 Technical data)
Never service the pump when it is hot.
Always ensure the pump and pipelines are de-pressurised when the pump is serviced.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
Always ensure the power supply is disconnected (in an off position) and is locked out to prevent
accidental operation.
!
Please refer to drive and coupling operating manuals supplied with the unit for maintenance
instructions.
Always ensure pump and ancillary equipment has been allowed to cool before touching
200002348-1-EN-GB 11
Safety 3 EN

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 its upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
Always use suitable transport device i.e. forklift truck or pallet lifter
200002348-1-EN-GB12
3 SafetyEN

4 Installation
4.1 Unpacking, handling and storage
Always ensure any personnel undertaking lifting operations have the suitable experience and training to do so
safely.
Ensure any lifting equipment used is in good condition and has been suitably tested, using lifting lugs when
applied.
Ensure any lifting equipment used is rated for and used within the load limits. Refer to the pump weights
guide.
Always ensure that the lifting points are in line with the centre of gravity and adjust lifting point if necessary.
Always keep an eye on the load and stay clear during the lifting operation.
The diagrams below show examples of how the equipment should be lifted, however the user is to ensure this
can be done safely with the equipment at hand:
Pump with drive unit
3206-0002
3206-0003
Bareshaft pump (typical location of centre of gravity shown)
3206-0004
3206-0005
200002348-1-EN-GB 13
EN

On receipt always:
– Check the delivery note against the goods received.
– If motorised, check that the drive instructions are available.
– Be careful not to discard any manuals that may be enclosed with the packaging.
– Inspect the packing for signs of damage in transit.
– Carefully remove the packing away from the pump
– Inspect the pump for any visible signs of damage.
– Clean away the packing from the pump port connections.
– Report any damage immediately to the carrier.
After receipt and inspection, if the pump is not to be installed immediately, the pump should be repacked in the
original packaging and placed in suitable storage. The following points should be noted:
– Plastic or gasket type port covers should be left in place.
– A clean, dry storage location free from vibration and without direct sunlight or UV light should be selected.
– Temperature range of between -5 to +40oC
– Relative humidity <60%
– If a moist or dusty atmosphere is used for storage, further protect the pump or unit with a suitable cover.
– No exposure to corrosive substances, including those contained in the air.
– Rotate the pump/pump unit by hand weekly, to prevent bearing damage.
– All associated ancillary equipment should be treated similarly.
4.2 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.
End of life
• 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
within a proper manner. When in doubt, or in the absence of local regulations, please contact the
local Alfa Laval sales company.
200002348-1-EN-GB
14
4 InstallationEN

4.3 System design, installation and operation
When designing, installing and operating pipework systems where pumps are used, especially where
the pumped media is viscous, there are general recommendations and good engineering practices
that should be employed to ensure long term, reliable pump and system operation.
Design
- Confirm the Net Positive Suction Head (NPSH) available from the system exceeds the NPSH
required by the pump, as this is crucial for ensuring the smooth operation of the pump and preventing
cavitation.
- Avoid suction lifts and manifold/common suction lines for two pumps running in parallel, as this may
cause vibration and/or cavitation.
- Protect the pump against blockage from hard solid objects e.g. nuts, bolts welding slag etc. Also
protect the pump from accidental operation against a closed valve by using relief valves, pressure
switches or current limiting devices.
- Fit suction and discharge pressure monitor points for diagnostic purposes.
- Fit valves, it two pumps are to be used on manifold/common discharge lines.
- Make the necessary piping arrangements if flushing is required for the seal.
- Allow at least 1 m for pump access/maintenance all around the pump.
To reduced the risk of damaged caused by sudden changes in temperature (thermal shock) ensure
any temperature changes are done gradually and equipment temperature is allowed to stabilise
before operation.
Pipework:
All pipework must be supported. The pump must not be allowed to support any of the pipework weight
beyond the limits set as shown in the following table.
Remember:
- Pipework supports must also support the weight of the product being pumped.
- Design short straight suction lines to reduce friction losses in the pipework thereby improving the
NPSH available from the system.
- Avoid bends, tees and any restrictions close to either suction or discharge side of pump. Use long
radius bends wherever possible.
- Provide isolating valves on each side of the pump when necessary.
- Keep pipework horizontal where applicable to reduce air locks. Include eccentric reducers on
suctions lines.
200002348-1-EN-GB 15
Installation 4 EN

Table of Maximum Forces and Moments
3206-0006
X
Y
Z
Port Forces Moments
Size Units F (x, y or z) F (total) Units M (x, y or z) M (total)
25mm 1” N
Ibf
190
43
270
61
Nm
Ibf.ft
85
63
125
92
40mm 1.5” N
Ibf
255
57
360
81
Nm
Ibf.ft
115
85
170
125
50mm 2” N
Ibf
295
66
420
94
Nm
Ibf.ft
145
107
210
155
65mm 2.5” N
Ibf
360
81
510
115
Nm
Ibf.ft
180
133
263
194
80mm 3” N
Ibf
425
96
600
135
Nm
Ibf.ft
215
159
315
232
100mm 4” N
Ibf
505
114
720
162
Nm
Ibf.ft
260
192
385
284
150mm 5” N
Ibf
720
162
1020
229
Nm
Ibf.ft
385
284
365
417
NOTE
At no time shall the values of Fx, Fy and Fz or Mx, My and Mz be the maximum values
200002348-1-EN-GB
16
4 InstallationEN

Direction of flow:
The direction of flow is dictated by the direction of rotation of the drive shaft. Reversing the direction of
rotation will reverse the flow direction.
3206-0007
B
AB
A
3206-0008
BB
AA
A Suction
B Discharge
A Suction
B Discharge
Pump Lubrication:
The pump will be supplied pre-filled with food grade (NSF H-1) oil as standard.
Oil level must be checked with the pump static using the oil sight glass fitted to the side of the
gearbox.
The oil should be changed every 3000 hrs of operation or every 2 years, whichever is soonest.
Oil filling: Fill with oil through the filler plug to the mid level of in the sight glass.
NOTE
On horizontally ported pumps the sight glass must be fitted to the upper hole on the side of the
gearcase. Refer to Section 6 Technical data for oil quantities required.
3206-0009
ü
200002348-1-EN-GB 17
Installation 4 EN

Recommended Olis:
Food Grade Oil (NSF H-1)
-20oC to +150oC (-4oF to 302oF)
Mobil SHC Cibus 150
Bel-Ray No-Tox HD 150 #62686
Castrol Optileb GT 150
Klüber Klüberoil 4 UH1-150 N
Fusch Cassida GL / GLE 150
Mobil Glygole 150 (US/CAN)
All oils are poly-alpha-olefin based please check compatibility before mixing with other base oils.
Baseplate Foundations
Pumps when supplied with a drive unit are normally mounted on a baseplate. Alfa Laval standard
positive displacement pump baseplates have pre-drilled fixing holes to accept base retaining bolts. To
provide a permanent rigid support for securing the pump unit, a foundation is required which will also
absorb vibration, strain or shock on the pumping unit. Methods of anchoring the baseplate to the
foundation are varied, they can be studs embedded in the concrete either at the pouring stage as
shown below, or by use of epoxy type grouts. Alternatively, mechanical fixings can be used.
Ensure the floor is able to support the weight of the pump unit.
Dmin
3D
D
a
b
3206-0010
0.5 Dmin
c
4D
3206-0011
10D
a
a Sleeve
b Lug welded to bolt head
c Waste put around bolt before pouring concrete
a Foundation surface left through to anchor ground
The drawing above shows two typical methods for foundation bolt retaining. The sleeve allows for
“slight” lateral movement of the bolts after the foundation is poured. Rag or wastepaper can be used
to prevent the concrete from entering the sleeve while the foundation is poured. A minimum of 14
days is normally required to allow the curing of the concrete prior to pump unit installation.
200002348-1-EN-GB
18
4 InstallationEN

Ball Foot Baseplate with Adjustable Feet
The pump can be supplied with an optional ball foot baseplate with height adjustable feet.
When used:
Ensure the floor is level and is able to support the weight of the complete unit
Ensure the unit is supported by all feet equally
3A Approved Ball Foot Baseplate with Adjustable Feet
For 3A approved mounted pumps a 3A approved ball foot baseplate is required which has additional
sealant applied to the underside.
3205-0054
Fully sealed underneath
Coupling alignment:
Before the pump unit is installed is it important to ensure that the mounting surface is flat to avoid
distortion of the baseplate, which may cause pump/motor shaft misalignment and pump/motor unit
damage. Once the baseplate has been secured, the pump shaft to motor shaft coupling alignment
should be checked and adjusted as necessary. This is achieved by checking the maximum angular
and parallel misalignment for the couplings as stated below. Shaft alignment that is outside the stated
tolerances can be corrected by applying shims under the motor or pump foot, or, by moving the pump
or drive sideways on the baseplate. All bolts that have been loosened should be re-tightened to the
stated torque figure.
The following dimensions and tolerances apply to standard supply couplings only (Fenner HRC Type).
Recommended bolt torques for pump and motor mounting.
Thread
Diameter M6 M8 M10 M12 M16 M20 M24
Torque (Nm) 6 15 30 50 120 150 200
Torque (ft lbf) 4.4 11.0 22.1 36.8 88.5 110.6 147.5
200002348-1-EN-GB 19
Installation 4 EN

Parallel Misalignment
Measure 4 positions at 90° around coupling
Coupling size Dimension A Maximum
A
3206-0012
70 0.3 mm
90 0.3 mm
110 0.3 mm
130 0.4 mm
150 0.4 mm
180 0.4 mm
230 0.5 mm
280 0.5 mm
Angular Misalignment
Measure 4 positions at 90° around coupling
Coupling size Dimension A Maximum
3206-0013
Bo
70 1°
90 1°
110 1°
130 1°
150 1°
180 1°
230 1°
280 1°
Assembled length
Coupling size Dimension A Maximum
L
3206-0013
70 25
90 30.5
110 45
130 53
150 60
180 75
230 85.5
280 105.5
200002348-1-EN-GB20
4 InstallationEN