Alfalaval LKH Prime UltraPure User manual

3013-0079
ESE03177-EN3 2018-02
Original manual
Instruction Manual
LKH Prime UltraPure 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 ......................................................................................... 8
3.3. Pre-check .......................................................................................... 11
3.4. Recycling information ............................................................................. 13
4. Operation ............................................................................................... 14
4.1. Operation/control ................................................................................. 14
4.2. Trouble shooting .................................................................................. 16
4.3. Recommended cleaning ......................................................................... 17
5. Maintenance ........................................................................................... 19
5.1. General maintemance ............................................................................ 19
5.2. Cleaning procedure ............................................................................... 21
5.3. Dismantling of pump/shaft seals ................................................................ 22
5.4. Assembly of pump/single shaft seal ............................................................ 26
5.5. Assembly of pump/double mecanical shaft seal .............................................. 29
5.6. Adjustment of shaft ............................................................................... 32
6. Technical data ......................................................................................... 34
6.1. Technical data ..................................................................................... 34
6.2. Relubrication intervals ............................................................................ 35
6.3. Torque specifications ............................................................................. 38
6.4. Weight (kg) ........................................................................................ 38
6.5. Noise emission .................................................................................... 39
7. Part list and service kits .............................................................................. 41
7.1. LKH Prime UltraPure ............................................................................. 41
7.2. LKH Prime UltraPure 20 - Product wetted parts .............................................. 42
7.3. LKH Prime UltraPure 20 - Motor-dependent parts ............................................ 44
7.4. LKH Prime UltraPure 20 - Shaft seal ............................................................ 46
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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 declares that
Pump
Designation
LKH Prime UP 20
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 2016-02-01
Place Date Signature
4

2 Safety
This manual highlights unsafe practices and other important information.
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 in order to avoid severe personal injury and/or damage to the pump.
2.3 Safety precautions
Installation:
Always read the technical data carefully. (See chapter 6.1 Technical data) !
Always use a lifting crane when handling the pump.
Always remove the air screw and impeller before checking the direction of rotation.
Never start the pump if the impeller and air screw are fitted and the pump casing is removed.
Operation:
Always read the technical data carefully. (See chapter 6.1 Technical data) !
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never run the pump when both the suction side and the pressure side are blocked.
Never run the pump when partially installed or not fully 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 listed 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 carefully. (See chapter 6.1 Technical data) !
Never service the pump when it is hot.
Never service the pump if pressurised.
Always use genuine spare parts from Alfa Laval.
Motors with grease nipples:
Remember to perform lubrication in accordance with the 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 that described in this manual
Always drain the pump head and accessories of any liquid
Always ensure that lubricants are not able to leak
Always transport the pump in an upright position
Always ensure that the unit is securely fixed during transportation
Always use the original packaging or similar during transportation
6

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
The pump is heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
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 injury to feet or fingers. The pump should be supported
underneath the adapter, 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 outlet.
Avoid damaging the inlet and 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
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
The pump is 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 carefully.
(See chaper 6.1 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 colours 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
may cause a hazardous situation to arise, precautions
must be taken e.g. a check valve can be installed in
the system to prevent hazardous situations.
Note:
The 3A standard requires minimum clearance
between the lowest part of the base, pump, motor or
drive and for the floor to be no less than 4 in. (100
mm)
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
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
The pump is 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
Correct Few bends
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 the event of leakage at the shaft seal, the medium will drip from
the slot into the bottom of the adapter. In this instance, Alfa Laval
recommends placing a drip tray underneath the slot to collect
the liquid.
Step 6
To ensure optimal function of the selfpriming capacity, LKH Prime
must be installed in such a way that ensures liquid is in the pump
on start-up e.g. with a swan neck design as illustrated.
Note
Max running time when releasing air only should not exceed 15
min.
D = Min. 1,5 m 2” pipe
S=200mm
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
The pump is heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
Step 7
If pump is fitted with drain option;
Never short circuit. the drain connections as this will reduce the
air release capacity.
Always use two drain valves.
Incorrect Correct
10

3 Installation
Read 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-check
Step 1
!
Always remove air screw and impeller before checking the
direction of rotation.
!
Never start the pump if the impeller is fitted and the pump casing
is removed.
1. Remove adapter shields (22)
2. Loosen unions and remove recirculation pipe (56)
3. Remove clamp (57) and front cover (60)
4. Remove air screw (58) with a spanner. Counter hold with a
screwdriver. (See also instruction in section 5.3)
5. Unscrew cap nuts (24). Remove washers (24a) and pump
casing (29)
6. Remove impeller (27). (See also instruction in section 5.3)
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 the impeller (27).
11

3 Installation
Read 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.
Step 4
1. Fit pump casing (29) and washers (24a). Fit and tighten cap
nuts (24). Torque = 20Nm/15 lbf-ft
2. Fit air screw (58) and tighten with a spanner (Torque = 20Nm
(15 lbf-ft))
3. Fit front cover O-ring (59) and fit and align front cover (60). Fit
clamp and tighten screws (57) gently
4. Fit recirculations pipe (56), align front cover (60) and tighten
unions
5. Tighten clamp screws (57)
6. Fit the apaptor shields (22)
12

3 Installation
Read 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.
3.4 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 wearing parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn 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. In addition to the equipment itself,
any hazardous residue from the process liquid must be taken into account and handled in the necessary way. 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 carefully. See chapter 6.1 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect operation/control.
Step 2
!
Never touch the pump or pipelines when pumping hot liquids
or when sterilising.
Risk of burns!
Step 3
!
Never run the pump when both the suction side and pressure
side are blocked.
Risk of explosion!
!
See the
warning
label!
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
Do not
allow to
run dry
14

4Operation
Read the instructions carefully and pay special attention to the warnings!
Step 5
Double mechanical shaft seal:
1. Connect the inlet of the flushing liquid correctly.
(R1/8”)
2. Regulate the water supply correctly
O: Outlet
I: Inlet
Tmax = 70°C
Pmax =5bar
(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 (when not releasing air)
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
-Abr
asive particles in the liquid - Select stationary and rotating seal ring
in silicon carbide/silicon carbide
- Use of incorrect SiC/SiC single seal - Change to SiC/SiC seal marked “LKH
Prime”
Leaking O-ring seals Incorrect rubber grade Change rubber grade
No/little air release - Pump not properly primed - Ensure pump is primed
- Pump speed too low - Increase pump speed during air
release
16

4Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Read 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.
Risk 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
⇒Dispense gradually!
2. Adapt 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

4Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Read the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
NOTE:
If pumps are sterilised using steam, standard 3A requires the process system to be designed to automatically shut down if
the product pressure in the system becomes less than that of the atmosphere and it cannot be started until the system is
re-sterilised.
18

5 Maintenance
Maintain the pump with care. Read the instructions carefully and pay special attention to the warnings!
Always have spare shaft seals and rubber seals to hand.
See separate motor instructions.
Check the pump for smooth operation after service.
5.1 General maintemance
Step 1
!
Always read the technical data carefully. (See section 6.1)
Always disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored//disposed of in accordance with current regulations/directives.
Step 2
!
Never service the pump when it is hot.
Risk of burns!
Step 3
!
Never service the 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 section 7).
Ordering spare parts
Contact your local Alfa Laval sales company.
19

5 Maintenance
Maintain the pump with care. Read the instructions carefully and pay special attention to the warnings!
Always have spare shaft seals and rubber seals to hand.
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
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 3.2 Installation).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
20