Alfalaval LKH Evap ESE01861-EN4 User manual

3000-0059
ESE01861-EN4 2016-10
Original manual
Instruction Manual
LKH Evap
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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 ......................................................................................... 8
3.3. Pre-use check ..................................................................................... 10
3.4. Recycling information ............................................................................. 11
4. Operation ............................................................................................... 12
4.1. Operation/Control ................................................................................. 12
4.2. Trouble shooting .................................................................................. 14
4.3. Recommended cleaning ......................................................................... 15
5. Maintenance ........................................................................................... 16
5.1. General maintenance ............................................................................. 16
5.2. Cleaning Procedure ............................................................................... 18
5.3. Dismantling of pump/shaft seals ................................................................ 19
5.4. Assembly of pump/single shaft seal ............................................................ 21
5.5. Assembly of pump/flushed shaft seal ........................................................... 24
5.6. Assembly of pump/double mechanical shaft seal ............................................. 27
5.7. Adjustment of shaft ............................................................................... 30
6. Technical data ......................................................................................... 33
6.1. Technical data ..................................................................................... 33
6.2. Relubrication intervals ............................................................................ 34
6.3. Torque Specifications ............................................................................. 37
6.4. Weight (kg) ........................................................................................ 37
6.5. Noise emission .................................................................................... 38
7. Parts list and service kits ............................................................................ 39
7.1. LKH Evap .......................................................................................... 39
7.2. LKH Evap - Wet end ............................................................................. 40
7.3. LKH Evap - Motor dependent parts ............................................................ 42
7.4. LKH Evap - Shaft seal ............................................................................ 44
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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
LKHevap-10, LKHevap-15, LKHevap-20, LKHevap-25, LKHevap-35, LKHevap-40, LKHevap-45, LKHevap-50, LKHevap-60, LKHevap-70, LKHevap-75
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
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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:
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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 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 Alfa Laval pump selection program.
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 pressurized.
Motors with grease nipples:
Remember lubrication according to information plate/label on the motor.
Always disconnect the power supply when servicing the pump.
Always use Alfa Laval genuine spare parts.
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
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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 thereby
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 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.
3000-0060
Remove
packing
materials!
Caution!
Step 3
Inspect the pump for visible transport damages. Inspection!
3000-0060
Step 4
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before lifting!
3000-0061
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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.
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 authorised
personnel. (See the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
WARNING:
Alfa Laval recommend the installation of 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 valve to be installed in the
system preventing above described.
Step 2
Ensure at least 0.5 m (1.6 ft) clearance around the pump.
3000-0063
Step 3
Check that the flow direction is correct.
O: Outlet
I: Inlet
3000-0064
O
I

Correct!
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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.
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!
3000-0065 Few bends
Correct!
Step 5
Avoid stressing the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
3000-0066
!
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 to put a drip tray underneath the slot for collecting the leakage.
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3 Installation
Study the instructions carefully and pay special attention to the warnings!
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check
Check direction of rotation
!
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.
Correct
3000-0071

View from rear end of motor
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3 Installation
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 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.
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4Operation
Study 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!
3000-0072
Step 3
!
Never run the pump with both the suction side and the pressure
side blocked.
Danger of explosion!
!
3000-0073
!
!
See the
warning label!
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4Operation
Study 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
3000-0074


Wrong
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.
O: Free outlet
I: Inlet
3000-0075_1

O
I
Tmax = 100°C
Pmax =1bar(flushseal)
Pmax = 5 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!
3000-0076
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4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Trouble shooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts.
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 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!
3000-0072
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
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 4
!
Always rinse well with clean water after using a cleaning agent.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agent
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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.
Danger of burns!
3000-0072
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)
CAUTION
Pay special attention to the warnings!
3000-0077
Atmospherie pressure
required!
Step 4
Recommended spare parts:
Order Service Kits from Service kits list
(See chapter 7 Parts list and service kits).
Ordering spare parts
Contact your local Alfa Laval sales company.
Note:
If pump is supplied with FEP O-rings. Alfa Laval recommend the casing O-ring is replaced when the pump is maintained.
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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 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 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).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
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5 Maintenance
5.2 Cleaning Procedure
Cleaning Procedure for Soiled Impeller Screw Tapped Hole:
1. Remove stub shaft (7) per section 4 of Service manual.
2. Submerge and soak 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 sanitizer 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 thru 6 above until swab test is passed.
Should swab testing continue to fail, or time is of the essence, install a new (spare) Stub Shaft (7).
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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 Dismantling of pump/shaft seals
Step 1
1. Unscrew cap nuts (24) and remove washers (24a) and pump
casing (29).
3000-0078_2
Step 2
Remove screw (23) and safety guard (22).
3000-0080
Step 3
Flushed / Double Mechanical shaft seal:
Unscrew fittings (42) using a spanner.
3000-0160
Step 4
1. Remove impeller screw (39).
2. Remove impeller (36/37). If necessary, loosen the impeller by
knocking gently on the impeller vanes.
3. Remove the O-ring (38) from the impeller.
Counterhold with a screwdriver!
3000-0081
If necessary!
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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 5
1. Pull off the O-ring (26) from back plate (25).
2. Unscrew nuts (20) and remove washers (21) and the back plate.
3000-0082
Step 6
1. Remove the stationary seal ring (11).
2. Remove the O-ring (12) from back plate (25). Use the tool
supplied
3000-0083
Left hand thread!
Step 7
Flushed shaft seal:
1. Remove screws (41) and seal housing (40).
2. Pull out lip seal (43) from the seal housing.
3000-0084
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 Evap-70 to 75: Remove cups (54) from rotating seal rings.
3000-0085
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). 3000-0086
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).
3000-0087
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