Alfalaval LKH-5 User manual

3000-0059
ESE00698-EN21 2017-05
Original manual
Instruction Manual
LKH Centrifugal Pump

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. Installation ......................................................................................... 9
3.3. Pre-use check - pump without impeller screw ................................................. 11
3.4. Pre-use check - pump with impeller screw .................................................... 12
3.5. Recycling information ............................................................................. 13
4. Operation ............................................................................................... 14
4.1. Operation/Control ................................................................................. 14
4.2. Trouble shooting .................................................................................. 16
4.3. Recommended cleaning ......................................................................... 17
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Cleaning Procedure ............................................................................... 20
5.3. Dismantling of pump/shaft seals ................................................................ 21
5.4. Assembly of pump/single shaft seal ............................................................ 24
5.5. Assembly of pump/flushed shaft seal ........................................................... 27
5.6. Assembly of pump/double mechanical shaft seal ............................................. 30
5.7. Adjustment of shaft (LKH-5) ..................................................................... 33
5.8. Adjustment of shaft (LKH-10 to -90) ............................................................ 35
6. Technical data ......................................................................................... 37
6.1. Technical data ..................................................................................... 37
6.2. Relubrication intervals ............................................................................ 38
6.3. Torque Specifications ............................................................................. 41
6.4. Weight (kg) ........................................................................................ 41
6.5. Noise emission .................................................................................... 42
7. Parts list and service kits ............................................................................ 43
7.1. LKH-5 Sanitary version ........................................................................... 43
7.2. LKH-10, -15, -20, -25, -35, -40, -50, -60, -70, -75, -85, -90 sanitary version ............. 44
7.3. LKH - Product wetted parts ..................................................................... 46
7.4. LKH - Motor-dependent parts ................................................................... 48
7.5. LKH - Shaft seal .................................................................................. 50
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Pump
Designation
LKH-5, LKH-10, LKH-15, LKH-20, LKH-25, LKH-35, LKH-40, LKH-45, LKH-50, LKH-60, LKH-70, LKH-85, LKH-90
Type
From serial number 10.000 to 1.000.000
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 2013-12-03
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised 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 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.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
5

2 Safety
All warnings in the manual are summarised 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 start in the wrong direction of rotation with liquid in the pump.
Always have the pump electrically connected by authorised personnel. (See the motor instruction)
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
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.
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.
Always handle lye and acid with great care.
Never use the pump for products not mentioned in the Alfa Laval pump selection program.
The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never service the pump when it is hot.
Never service the pump if pressurised.
Alwaysuse Alfa Laval genuine spare parts.
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 its upright position
Always ensure that the unit is securely fixed during transportation
Always use the original packaging or similar during transportation
6

3 Installation
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.
WARNING:
Be aware that certain pump configurations can tilt, and therefore
cause injuries to feet or fingers. The pump should be supported
underneath the adaptor, when not installed in the process line.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
Step 2
Remove any packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied. Remove
packing
materials!
Step 3
Inspect the pump for visible transport damage. Inspection!
Step 4
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before lifting!
7

3 Installation
Step 5
ONLY LKH-85 and LKH-90
Do NOT use eyebolt in casing to lift the pump. The eyebolt is
for casing removal only.
8

3 Installation
Read 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 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.
Always have the pump electrically connected by authorised
personnel. (See the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
WARNING:
Alfa Laval recommends the installation of a lockable repair
breaker. If the repair breaker is to be used as an emergency stop,
the colors of the repair breaker must be red and yellow.
Caution:
The pump does not prevent back flow when
intentionally or unintentionally stopped. If back flow
can cause any hazardous situations, precautions
must be taken e.g. check the valve to be installed
in the system preventing hazardous situations from
arising.
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
9

3 Installation
Read the instructions carefully and pay special attention to the warnings! Always check thepumpbeforeoperation.
- See pre-use check in section 3.3 Pre-use check - pump without impeller screw.
The large pump sizes are very heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings
Few bends
Correct
Step 5
Avoid stress on the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Note
In case of shaft seal leakage, the media will drip from the slot in the bottom of the adaptor. In case of shaft seal leakage, Alfa
Laval recommends putting a drip tray underneath the slot to collect the leakage.
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3 Installation
Read the instructions carefully and pay special attention to the warnings!
LKH-5 to -60 comes 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 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 -60: Remove cap nuts (24), washers (24a) and
pump casing (29).
2. Remove impeller (27) (see also instruction in section 5.4
Assembly of pump/single shaft seal).
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.
Stub shaft
Step 3
Fit and tighten impeller (27).
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 -60: Fit washers (24a) and tighten cap nuts (24),
according to torque values in chapter 6 Technical data
11

3 Installation
Read the instructions carefully and pay special attention to the warnings!
LKH-5 to -60 comes 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.
3.4 Pre-use check - 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.
View from rear end of
motor
12

3 Installation
Read the instructions carefully and pay special attention to the warnings!
LKH-5 to -60 comes 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.
3.5 Recycling information
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, 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 wearing 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 wearing parts must be disposed of in accordance with local regulations
Scrapping
- At the end of use, the equipment must be recycled according to relevant local regulations. Besides the equipment itself, any
hazardous residues from the process liquid must be taken into consideration and dealt with in a proper manner. When in
doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company.
13

4Operation
Read the instructions carefully and pay special attention to the warnings!
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.
Danger of burns!
Step 3
!
Never run the pump with both the suction side and the pressure
side blocked.
Danger of explosion!
!
See the
warning label!
14

4Operation
Read the instructions carefully and pay special attention to the warnings!
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
Do not allow to
run dry
Step 5
Double mechanical/flushed shaft seal:
1. Connect the inlet of the flushing liquid correctly. (R1/8”
BSP).
2. Regulate the water supply correctly.
For LKH-85: connect inlet/outlet of the flushing liquid directly on
the flushing housing. (ø6 tube).
O: Outlet
I: Inlet
Tmax =70°C
Pmax = 1 bar (flush seal)
Pmax LKH5-60=5bar
(double mechanical seal)
Pmax LKH 70-90 = 3 bar
(double mechanical seal)
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!
15

4Operation
Pay attention to possible faults.
Read the instructions carefully.
4.2 Trouble shooting
NOTE!
Read the maintenance instructions carefully before replacing worn parts.
Problem Cause/result Remedy
Motor overloaded - Pumping of viscous liquids - Larger motor or smaller impeller
- Pumping of high density liquids
- 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
- Increase in the noise level - Reduce the pressure drop before the
pump
- Reduce speed
Leaking shaft seal - Running dry Replace:
All wearing parts
- Incorrect rubber grade If necessary:
- Change rubber grade
- Abrasive particles in the liquid -Sel
ect stationary and rotating seal ring
in silicon carbide/silicon carbide
Leaking O-ring seals Incorrect rubber grade Change rubber grade
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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 sterilising.
Danger of burns!
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) +100l(26.4gal) =Cleaningagent.
NaOH water
2.2 l (0.6 gal) +100l(26.4gal) =Cleaningagent.
33% NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100l(26.4gal) =Cleaningagent.
53% HNO3water
1. Avoid excessive concentration
of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the
process.
Sterilisation of milk/viscous
liquids
⇒Increase the cleaning flow!
Step 4
!
Always rinse well with clean water after using a cleaning agent.
NOTE
Cleaning agents must be stored/disposed of in accordance with
current regulations/directives.
Always rinse!
Clean water Cleaning agent
17

5 Maintenance
Maintain the pump with care. Read 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//disposed of in accordance with current rules/directives.
Step 2
!
Never service the pump when it is hot.
Danger of burns!
Step 3
!
Never service the pump with pump if pressurised.
CAUTION
Fit the electrical connections correctly if they have been removed
from the motor during service.
CAUTION
Pay special attention to the warnings!
Atmospheric pressure
required!
Step 4
Recommended spare parts:
Order service kits from the service kits list
(See chapter 7 Parts list and service kits).
Ordering spare parts
Contact your local Alfa Laval sales company.
Note:
If the pump is supplied with FEP O-rings, Alfa Laval recommends that the casing O-ring is replaced during pump maintenance.
18

5 Maintenance
Maintain the pump with care. Read 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 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
inspection planning
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 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 servicing.
(See pre-use check in section 3 Installation).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
19

5 Maintenance
5.2 Cleaning Procedure
Cleaning procedure for soiled impeller screw tapped hole:
1. Remove stub shaft (7) as per section 4 of the Service manual.
2. Submerge and soak the stub shaft for 5 minutes in COP tank with 2% caustic wash
3. Scrub the blind tapped impeller screw hole vigorously by plunging a clean 1/2” diameter sanitary bristle pipe brush in and out
of the hole for two minutes while submerged.
4. Soak stub shaft (7) in acid sanitiser for 5 minutes, then scrub blind tapped hole as described in step 3 above.
5. Rinse well with clean water and blow-dry blind tapped hole with clean air.
6. Swab test the inside of the tapped hole to determine cleanliness.
7. Should the swab test fail, repeat steps 2 to 6 above until the swab test is passed.
Should swab testing continue to fail, or time is of the essence, install a new (spare) stub shaft (7).
20