Alfalaval LKH Evap User manual

ESE01861-EN72022-10
Originalmanual
InstructionManual
LKHEvap

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetprecautions................................................................................7
3.Installation....................................................................................9
3.1.Unpacking/deliver...............................................................................9
3.2.Installation.........................................................................................10
3.3.Pre-usecheck.....................................................................................12
3.4.Recclinginformation.............................................................................13
4.Operation.....................................................................................14
4.1.Operation/Control.................................................................................14
4.2.Troubleshooting..................................................................................16
4.3.Recommendedcleaning.........................................................................17
5.Maintenance..................................................................................18
5.1.Generalmaintenance.............................................................................18
5.2.CleaningProcedure...............................................................................20
5.3.Dismantlingofpump/shaftseals................................................................21
5.4.Assemblofpump/singleshaftseal............................................................23
5.5.Assemblofpump/flushedshaftseal...........................................................26
5.6.Assemblofpump/doublemechanicalshaftseal.............................................29
5.7.Adjustmentofshaft...............................................................................32
6.Technicaldata................................................................................35
6.1.Technicaldata.....................................................................................35
6.2.Relubricationintervals............................................................................36
6.3.TorqueSpecifications.............................................................................39
6.4.Weight(kg)........................................................................................39
6.5.Noiseemission....................................................................................40
7.Partslistandservicekits...................................................................41
7.1.LKHEvap..........................................................................................41
7.2.LKHEvap-Wetend.............................................................................42
.............................................................................................................46
7.4.LKHEvap-Shaftseal............................................................................48
3

1DeclarationsofConformity
EU EU
EUDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Pump
Designation
LKHevap-10,LKHevap-15,LKHevap-20,LKHevap-25,LKHevap-35,LKHevap-40,LKHevap-45,LKHevap-50,LKHevap-60,LKHevap-70,
LKHevap-75
Tpe
Serialnumberfrom10.000to1.000.000
isinconformitwiththefollowingdirectiveswithamendments:
-MachinerDirective2006/42/EC
-RoHSEUDirective2011/65/EUandamendments
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformitreplacesDeclarationofConformitdated2013-12-03
4

1DeclarationsofConformity
UK UK
UKDeclaration Declaration Declarationof of ofConformit Conformit Conformit
TheDesignatedCompan
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companname,addressandphonenumber
Herebdeclarethat
Pump
Designation
LKHevap-10,LKHevap-15,LKHevap-20,LKHevap-25,LKHevap-35,LKHevap-40,LKHevap-45,LKHevap-50,LKHevap-60,LKHevap-70,
LKHevap-75
Tpe
Serialnumberfrom10.000to1.000.000
isinconformitwiththefollowingdirectiveswithamendments:
-TheSupplofMachiner(Safet)Regulations2008
-TheRestrictionoftheUseofCertainHazardousSubstancesinElectricalandElectronicEquipmentRegulations2012
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualitManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Unsafepracticesandotherimportantinformationareemphasisedinthismanual.
Warningsareemphasisedbymeansofspecialsigns.
Always Always
Alwaysread read readthe the themanual manual manualbefore before beforeusing using usingthe the thepump! pump! pump!
2.1Importantinformation
W W
WARNING ARNING ARNING
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjur.
CAUTION CAUTION
CAUTION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothepump.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimpliforclarifprocedures.
2.2Warningsigns
Generalwarning:
Dangerouselectricalvoltage:
Causticagents:
6

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothepumpareavoided.
2.3Safetyprecautions
Installation: Installation:
Installation:
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.(Seechapter6Technicaldata)
Alwas Alwas
Alwasusealiftingcranewhenhandlingthepump.
Pump Pump
Pumpwith with withImpeller Impeller Impellerscr scr screw: ew: ew:
Never Never
Neverstartinthewrongdirectionofrotationwithliquidinthepump.
Alwas Alwas
Alwashavethepumpelectricallconnectedbauthorisedpersonnel.(Seethemotorinstruction)
Operation: Operation:
Operation:
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.(Seechapter6Technicaldata)
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquidsorwhensterilising.
Never Never
Neverrunthepumpwithboththesuctionsideandthepressuresideblocked.
Never Never
Neverrunthepumpwhenpartiallinstalledornotcompletelassembled.
Necessar Necessar
Necessarprecautionsmustbetakenifleakageoccursasthiscanleadtohazardoussituations.
Alwas Alwas
Alwashandleleandacidwithgreatcare.
Never Never
NeverusethepumpforproductsnotmentionedinAlfaLavalpumpselectionprogram.
AlfaLavalpumpselectionprogramcanbeacquiredfromourlocalAlfaLavalsalescompan.
Maintenance: Maintenance:
Maintenance:
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.(Seechapter6Technicaldata)
Never Never
Neverservicethepumpwhenitishot.
Never Never
Neverservicethepumpifpressurized.
Motors Motors
Motorswith with withgr gr grease ease easenipples: nipples: nipples:
Rememberlubricationaccordingtoinformationplate/labelonthemotor.
Alwas Alwas
Alwasdisconnectthepowersupplwhenservicingthepump.
Alwas Alwas
AlwasuseAlfaLavalgenuinespareparts.
T T
Transportation: ransportation: ransportation:
T T
Transportation ransportation ransportationof of ofthe the thepump pump pumpor or orthe the thepump pump pumpunit: unit: unit:
Never Never
Neverliftorelevateinanwaotherthandescribedinthismanual
Alwas Alwas
Alwasdrainthepumpheadandaccessoriesofanliquid
Alwas Alwas
Alwasensurethatnoleakageoflubricantscanoccur
7

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowsothatseverepersonalinjuryand/ordamagetothepumpareavoided.
Alwas Alwas
Alwastransportthepumpinit'suprightposition
Alwas Alwas
Alwasensurethattheunitissecurelfixedduringtransportation
Alwas Alwas
Alwasuseoriginalpackagingorsimilarduringtransportation
8

3Installation
3.1Unpacking/delivery
Step Step
Step1 1 1
Alwasusealiftingcranewhenhandlingthepump(Seetechnical
data).
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
W W
WARNING: ARNING: ARNING:
Beawarethatcertainpumpconfigurationscantilt,andthereb
causeinjuriestofeetorfingers.Thepumpshouldbesupported
underneaththeadaptor,whennotinstalledintheprocessline.
Check Check
Checkthe the thedeliver deliver deliverfor: for: for:
1.Completepump.
2.Delivernote.
3.Motorinstructions.
Step Step
Step2 2 2
Removeanpossiblepackingmaterialsfromtheinletandthe
outlet.
Avoiddamagingtheinletandtheoutlet.
Avoiddamagingtheconnectionsforflushingliquid,ifsupplied.Remove
packing
materials!
Caution!
Step Step
Step3 3 3
Inspectthepumpforvisibletransportdamages.Inspection!
Step Step
Step4 4 4
Alwasremovetheshroud,iffitted,beforeliftingthepump.Removetheshroudbeforelifting!
9

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.
Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
3.2Installation
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.(Seechaper6
Technicaldata)
Alwas Alwas
Alwasusealiftingcranewhenhandlingthepump.(Seechaper
6Technicaldata)
Alwas Alwas
Alwashavethepumpelectricallconnectedbauthorised
personnel.(Seethemotorinstructions).
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
W W
WARNING: ARNING: ARNING:
AlfaLavalrecommendtheinstallationoflockablerepairbreaker.If
therepairbreakeristobeusedasanemergencstopthecolors
oftherepairbreakermustberedandellow.
Caution: Caution:
Caution:
Thepumpdoesnotpreventbackflowwhen
intentionallorunintentionallstopped.Ifbackflow
cancauseanhazardoussituationsprecautions
mustbetakene.g.checkvalvetobeinstalledinthe
sstempreventingabovedescribed.
Step Step
Step2 2 2
Ensureatleast0.5m(1.6ft)clearancearoundthepump.
Step Step
Step3 3 3
Checkthattheflowdirectioniscorrect.
O:Outlet
I:Inlet
Correct!
10

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayschecthepumpbeforeoperation.
-Seepre-usechecinsection3.3Pre-usechec.
Thelargepumpsizesareveryheavy.AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Step Step
Step4 4 4
1.Ensurethatthepipelinesareroutedcorrectl.
2.Ensurethattheconnectionsaretight.
Remembersealrings!
Fewbends
Correct!
Step Step
Step5 5 5
Avoidstressingthepump.
Paspecialattentionto:
-Vibrations.
-Thermalexpansionofthetubes.
-Excessivewelding.
-Overloadingofthepipelines.
Note Note
Note
Incaseofshaftsealleakage,themediawilldripfromtheslotinthebottomoftheadaptor.Incaseofshaftsealleakage,Alfa
Lavalrecommendstoputadriptraunderneaththeslotforcollectingtheleakage.
11

3Installation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Checthedirectionofrotationoftheimpellerbeforeoperation.
-Seetheindicationlabelonthepump.
3.3Pre-usecheck
Check Check
Checkdir dir direction ection ectionof of ofr r rotation otation otation
Never Never
Neverstartinthewrongdirectionofrotationwithliquidinthepump.
1.Startandstopthemotormomentaril.
2.Ensurethatthedirectionofrotationofthemotorfanisclockwiseasviewedfromtherearendofthemotor.
Correct
Viewfromrearendofmotor
12

3Installation
3.4Recyclinginformation
• •
•Unpacking Unpacking Unpacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps.
-Woodandcardboardboxescanbereused,reccledorusedforenergrecover.
-Plasticsshouldbereccledorburntatalicensedwasteincinerationplant.
-Metalstrapsshouldbesentformaterialreccling.
• •
•Maintenance Maintenance Maintenance
-Duringmaintenanceoilandwearpartsinthemachinearereplaced.
-Allmetalpartsshouldbesentformaterialreccling.
-Wornoutordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialreccling.
-Oilandallnonmetalwearpartsmustbetakencareofinagreementwithlocalregulations.
• •
•Scrapping Scrapping Scrapping
-Atendofuse,theequipmentshallbereccledaccordingtorelevant,localregulations.Besidetheequipmentitself,an
hazardousresiduesfromtheprocessliquidmustbeconsideredanddealtwithinapropermanner.Whenindoubt,orinthe
absenceoflocalregulations,pleasecontactthelocalAlfaLavalsalescompan.
13

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Operation/Control
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.Seechapter6Technicaldata
CAUTION CAUTION
CAUTION
AlfaLavalcannotbeheldresponsibleforincorrectoperation/control.
Step Step
Step2 2 2
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquids
orwhensterilising.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Never Never
Neverrunthepumpwithboththesuctionsideandthepressure
sideblocked.
Danger Danger
Dangerof of ofexplosion! explosion! explosion!
See See
Seethe the the
war war
warning ning ninglabel! label! label!
14

4Operation
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step4 4 4
CAUTION CAUTION
CAUTION
Theshaftsealmustnotrundr.
CAUTION CAUTION
CAUTION
Never Never
Neverthrottletheinletside.
Do Do
Donot not notallow allow allow
to to
torun run rundr dr dr
Wrong
Step Step
Step5 5 5
Flushed Flushed
Flushedshaft shaft shaftseal: seal: seal:
1.Connecttheinletoftheflushingliquidcorrectl.
2.Regulatethewatersupplcorrectl.
3.Observethesteamdata.
O:Freeoutlet
I:InletTmax=100°C
Pmax=1bar(flushseal)
Pmax=5bar(double
mechanicalseal)
Step Step
Step6 6 6
Contr Contr
Control: ol: ol:
Reducethecapacitandthepowerconsumptionbmeansof:
-Throttlingthepressuresideofthepump.
-Reducingtheimpellerdiameter.
-Reducingthespeedofthemotor.
Throttling!
15

4Operation
Payattentiontopossiblefaults.
Studytheinstructionscarefully.
4.2Troubleshooting
NOTE! NOTE!
NOTE!
Studthemaintenanceinstructionscarefullbeforereplacingwornparts.
Pr Pr
Problem oblem oblemCause/r Cause/r
Cause/result esult esultRemed Remed
Remed
Overloadedmotor-Pumpingofviscousliquids-Largermotororsmallerimpeller
-Pumpingofliquidswithhighdensit
-Lowoutletpressure(counterpressure)-Highercounterpressure(throttling)
-Laminationofprecipitatesfromthe
liquid-Frequentcleaning
Cavitation:
-Damage-Lowinletpressure-Increasetheinletpressure
-Pressurereduction(sometimesto
zero)-Highliquidtemperature-Reducetheliquidtemperature
-Increasingofthenoiselevel-Reducethepressuredropbeforethe
pump
-Reducespeed
Leakingshaftseal-DrrunReplace:
Allwearingparts
-IncorrectrubbergradeIfnecessar:
-Changerubbergrade
-Abrasiveparticlesintheliquid-Selectstationarandrotatingsealring
insiliconcarbide/siliconcarbide
LeakingO-ringsealsIncorrectrubbergradeChangerubbergrade
16

4Operation
Thepumpisdesignedforcleaninginplace(CIP).CIP=CleaningInPlace.
Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
NaOH=CausticSoda.
HNO3=Nitricacid.
4.3Recommendedcleaning
Step Step
Step1 1 1
Alwas Alwas
Alwashandleleandacidwithgreatcare.
Caustic Caustic
Causticdanger! danger! danger!
Alwasuserubbergloves!Alwasuseprotective
goggles!
Step Step
Step2 2 2
Never Never
Nevertouchthepumporthepipelineswhensterilising.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Examples Examples
Examplesof of ofcleaning cleaning cleaningagents: agents: agents:Usecleanwater,freefromchlorides.
1.1%bweightNaOHat70°C(158°F).
1kg(2.2lb)+100l(26.4gal)=Cleaningagent.
NaOHwater
2.2l(0.6gal)+100l(26.4gal)=Cleaningagent.
33%NaOHwater
2.0.5%bweightHNO3at70°C(158°F).
0.7l(0.2gal)+100l(26.4gal)=Cleaningagent.
53%HNO3water
1.Avoidexcessiveconcentration
ofthecleaningagent
⇒Dosegraduall!
2.Adjustthecleaningflowtothe
process.
Sterilizationofmilk/viscous
liquids
⇒Increasethecleaningflow!
Step Step
Step4 4 4
Alwas Alwas
Alwasrinsewellwithcleanwaterafterusingacleaningagent.
NOTE NOTE
NOTE
Thecleaningagentsmustbestored/disposedofinaccordance
withcurrentregulations/directives.
Alwas Alwas
Alwasrinse! rinse! rinse!
CleanwaterCleaningagent
17

5Maintenance
Maintainthepumpcarefully.Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Alwayseepspareshaftsealsandrubbersealsinstoc.
Seeseparatemotorinstructions.
Checthepumpforsmoothoperationafterservice.
5.1Generalmaintenance
Step Step
Step1 1 1
Alwas Alwas
Alwasreadthetechnicaldatathoroughl.(Seechaper6Technicaldata)
Alwas Alwas
Alwasdisconnectthepowersupplwhenservicingthepump.
NOTE NOTE
NOTE
Allscrapmustbestored/dischargedinaccordancewithcurrentrules/directives.
Step Step
Step2 2 2
Never Never
Neverservicethepumpwhenitishot.
Danger Danger
Dangerof of ofbur bur burns! ns! ns!
Step Step
Step3 3 3
Never Never
Neverservicethepumpwithpumpandpipelinesunderpressure.
CAUTION CAUTION
CAUTION
Fittheelectricalconnectionscorrectlifthehavebeenremoved
fromthemotorduringservice.(See3.3Pre-usecheck)
CAUTION CAUTION
CAUTION
Paspecialattentiontothewarnings!
Atmospheriepressure
required!
Step Step
Step4 4 4
Recommended Recommended
Recommendedspar spar spare e eparts: parts: parts:
OrderServiceKitsfromServicekitslist
(Seechapter7Partslistandservicekits).
Or Or
Ordering dering deringspar spar spare e eparts parts parts
ContactourlocalAlfaLavalsalescompan.
Note: Note:
Note:
IfpumpissuppliedwithFEPO-rings.AlfaLavalrecommendthecasingO-ringisreplacedwhenthepumpismaintained.
18

5Maintenance
Maintainthepumpcarefully.Studytheinstructionscarefullyandpayspecialattentiontothewarnings!
Alwayseepspareshaftsealsandrubbersealsinstoc.
Seeseparatemotorinstructions.
Checthepumpforsmoothoperationafterservice.
Shaft Shaft
Shaftseal seal sealRubber Rubber
Rubberseals seals sealsMotorbearings
PreventivemaintenanceReplace Replace
Replaceafter after after12 12 12months: months: months:
(one-shift)Completeshaftseal
Replacewhenreplacingthe
shaftseal
Maintenanceafterleakage
(leakagenormallstartsslowl)
Replace Replace
Replaceat at atthe the theend end endof of ofthe the the
da: da:
da:Completeshaftseal
Replacewhenreplacingthe
shaftseal
Plannedmaintenance-Regularinspectionfor
leakageandsmooth
operation
-Keeparecordofthepump
-Usethestatisticsfor
planningofinspections
Replace Replace
Replaceafter after afterleakage: leakage: leakage:
Completeshaftseal
Replacewhenreplacingthe
shaftseal
Yearlinspectionis
recommended
-Replacecompletebearing
ifworn
-Ensurethatthebearingis
axialllocked(Seemotor
instructions)
LubricationBefor Befor
Before e efitting fitting fitting
LubricatetheO-ringswith
siliconegreaseorsiliconeoil
Befor Befor
Before e efitting fitting fitting
Siliconegreaseorsiliconeoil
Seesection6.2Relubrication
intervals
Pr Pr
Pre e e- - -use use usecheck check check
CAUTION! CAUTION!
CAUTION!
Fittheelectricalconnectionscorrectlifthehavebeenremovedfromthemotorduringservice.
(See3.3Pre-usecheck).
Pa Pa
Paspecial special specialattention attention attentionto to towar war warnings! nings! nings!
1.Startandstopthemotormomentaril
2.Ensurethatthepumpoperatessmoothl.
19

5Maintenance
5.2CleaningProcedure
Cleaning Cleaning
CleaningPr Pr Procedur ocedur ocedure e efor for forSoiled Soiled SoiledImpeller Impeller ImpellerScr Scr Screw ew ewT T Tapped apped appedHole: Hole: Hole:
1.Removestubshaft(7)persection4ofServicemanual.
2.SubmergeandsoakStubShaftfor5minutesinCOPtankwith2%causticwash
3.Scrubtheblindtappedimpellerscrewholevigorouslbplungingaclean1/2”diametersanitarbristlepipebrushinandout
oftheholefortwominuteswhilesubmerged.
4.SoakStubShaft(7)inacidsanitizerfor5minutes,thenscrubblindtappedholeasdescribedinstep3above.
5.Rinsewellwithcleanwaterandblow-drblindtappedholewithcleanair.
6.Swabtesttheinsideofthetappedholetodeterminecleanliness.
7.Shouldtheswabtestfail,repeatsteps2thru6aboveuntilswabtestispassed.
Shouldswabtestingcontinuetofail,ortimeisoftheessence,installanew(spare)StubShaft(7).
20