Alfalaval LKH Prime UltraPure User manual

ESE03177-EN72022-10
Originalmanual
InstructionManual
LKHPrimeUltraPurePump

Tableofcontents
Theinformationhereiniscorrectatthetimeofissuebutmaybesubjecttochangewithoutpriornotice
1.DeclarationsofConformity.................................................................4
2.Safety..........................................................................................6
2.1.Importantinformation.............................................................................6
2.2.Warningsigns.....................................................................................6
2.3.Safetyprecautions................................................................................7
3.Installation....................................................................................8
3.1.npacking/delivery...............................................................................8
3.2.Installation.........................................................................................9
3.3.Pre-check..........................................................................................16
3.4.Recyclinginformation.............................................................................18
4.Operation.....................................................................................19
4.1.Operation/control.................................................................................19
4.2.Troubleshooting..................................................................................21
4.3.Recommendedcleaning.........................................................................22
5.Maintenance..................................................................................24
5.1.Generalmaintemance............................................................................24
5.2.Cleaningprocedure...............................................................................26
5.3.Dismantlingofpump/shaftseals................................................................27
5.4.Assemblyofpump/singleshaftseal............................................................31
5.5.Assemblyofpump/doublemecanicalshaftseal..............................................35
5.6.Adjustmentofshaft...............................................................................39
6.Technicaldata................................................................................42
6.1.Technicaldata.....................................................................................42
6.2.Relubricationintervals............................................................................43
6.3.Torquespecifications.............................................................................43
6.4.Weight(kg)........................................................................................43
6.5.Noiseemission....................................................................................44
7.Partlistandservicekits.....................................................................45
7.1.LKHPrimeltraPure.............................................................................45
7.2.LKHPrimeltraPure20-Productwettedparts..............................................46
7.3.LKHPrimeltraPure20-Motor-dependentparts............................................48
7.4.LKHPrimeltraPure20-Shaftseal............................................................50
3

1DeclarationsofConformity
E E
EDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
LKHPrimeP10,LKHPrimeP20
Type
Serialnumberfrom10.000to1.000.000
SerialnumberfromAAB000000001toAAB999999999
isinconformitywiththefollowingdirectiveswithamendments:
-MachineryDirective2006/42/EC
-RoHSEDirective2011/65/Eandamendments
Thepersonauthorisedtocompilethetechnicalfileisthesignerofthisdocument.
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
ThisDeclarationofConformityreplacesDeclarationofConformitydated2020-06-01
4

1DeclarationsofConformity
K K
KDeclaration Declaration Declarationof of ofConformity Conformity Conformity
TheDesignatedCompany
AlfaLavalKoldingA/S,Albuen31,DK-6000Kolding,Denmark,[phone]
Companyname,addressandphonenumber
Herebydeclarethat
Pump
Designation
LKHPrimeP10,LKHPrimeP20
Type
Serialnumberfrom10.000to1.000.000
SerialnumberfromAAB000000001toAAB999999999
isinconformitywiththefollowingdirectiveswithamendments:
-TheSupplyofMachinery(Safety)Regulations2008
-TheRestrictionoftheseofCertainHazardousSubstancesinElectricalandElectronicEquipmentRegulations2012
Signedonbehalfof:AlfaLavalKoldingA/S
GlobalProductQualityManagerLarsKruseAndersen
TitleName
Kolding,Denmark2022–10–01
PlaceDate(YYYY-MM-DD)Signature
DoCRevison_01_102022
5

2Safety
Thismanualhighlightsunsafepracticesandotherimportantinformation.
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
Indicatesthatspecialproceduresmustbefollowedtoavoidseriouspersonalinjury.
CATION CATION
CATION
Indicatesthatspecialproceduresmustbefollowedtoavoiddamagetothepump.
NOTE NOTE
NOTE
Indicatesimportantinformationtosimplifyorclarifyprocedures.
2.2Warningsigns
General General
Generalwar war warning: ning: ning:
Danger Danger
Dangerous ous ouselectrical electrical electricalvoltage: voltage: voltage:
Caustic Caustic
Causticagents: agents: agents:
6

2Safety
Allwarningsinthemanualaresummarisedonthispage.
Payspecialattentiontotheinstructionsbelowinordertoavoidseverepersonalinjuryand/ordamagetothepump.
2.3Safetyprecautions
Installation: Installation:
Installation:
Always Always
Alwaysreadthetechnicaldatacarefully.(Seechapter6.1Technicaldata)
Always Always
Alwaysusealiftingcranewhenhandlingthepump.
Always Always
Alwaysremovetheairscrewandimpellerbeforecheckingthedirectionofrotation.
Never Never
Neverstartthepumpiftheimpellerandairscrewarefittedandthepumpcasingisremoved.
Operation: Operation:
Operation:
Always Always
Alwaysreadthetechnicaldatacarefully.(Seechapter6.1Technicaldata)
Never Never
Nevertouchthepumporthepipelineswhenpumpinghotliquidsorwhensterilising.
Never Never
Neverrunthepumpwhenboththesuctionsideandthepressuresideareblocked.
Never Never
Neverrunthepumpwhenpartiallyinstalledornotfullyassembled.
Necessary Necessary
Necessaryprecautionsmustbetakenifleakageoccursasthiscanleadtohazardoussituations.
Always Always
Alwayshandlelyeandacidwithgreatcare.
Never Never
NeverusethepumpforproductsnotlistedintheAlfaLavalpumpselectionprogram.
TheAlfaLavalpumpselectionprogramcanbeacquiredfromyourlocalAlfaLavalsalescompany.
Maintenance: Maintenance:
Maintenance:
Always Always
Alwaysreadthetechnicaldatacarefully.(Seechapter6.1Technicaldata)
Never Never
Neverservicethepumpwhenitishot.
Never Never
Neverservicethepumpifpressurised.
Always Always
AlwaysusegenuinesparepartsfromAlfaLaval.
Motors Motors
Motorswith with withgr gr grease ease easenipples: nipples: nipples:
Remembertoperformlubricationinaccordancewiththeinformationplate/labelonthemotor.
Always Always
Alwaysdisconnectthepowersupplywhenservicingthepump.
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
Neverliftorelevateinanywayotherthanthatdescribedinthismanual
Always Always
Alwaysdrainthepumpheadandaccessoriesofanyliquid
Always Always
Alwaysensurethatlubricantsarenotabletoleak
Always Always
Alwaystransportthepumpinanuprightposition
Always Always
Alwaysensurethattheunitissecurelyfixedduringtransportation
Always Always
Alwaysusetheoriginalpackagingorsimilarduringtransportation
7

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
3.1Unpacking/delivery
Step Step
Step1 1 1
Alwaysusealiftingcranewhenhandlingthepump(seetechnical
data).
CATION CATION
CATION
AlfaLavalcannotbeheldresponsibleforincorrectunpacking.
W W
WARNING: ARNING: ARNING:
Beawarethatcertainpumpconfigurationscantilt,andtherefore
causeinjurytofeetorfingers.Thepumpshouldbesupported
underneaththeadapter,whennotinstalledintheprocessline.
Check Check
Checkthe the thedelivery delivery deliveryfor: for: for:
1.Completepump
2.Deliverynote
3.Motorinstructions
Step Step
Step2 2 2
Removeanypackingmaterialsfromtheinletandoutlet.
Avoiddamagingtheinletandoutlet.
Avoiddamagingtheconnectionsforflushingliquid,ifsupplied.
Step Step
Step3 3 3
Inspectthepumpforvisibletransportdamage.
Step Step
Step4 4 4
Alwaysremovetheshroud,iffitted,beforeliftingthepump.
8

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
3.2Installation
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatacarefully.
(Seechaper6.1Technicaldata)
Always Always
Alwaysusealiftingcranewhenhandlingthepump.
Always Always
Alwayshavethepumpelectricallyconnectedbyauthorised
personnel.(Seethemotorinstructions).
CATION CATION
CATION
AlfaLavalcannotbeheldresponsibleforincorrectinstallation.
W W
WARNING: ARNING: ARNING:
AlfaLavalrecommendstheinstallationofalockablerepair
breaker.Iftherepairbreakeristobeusedasanemergencystop,
thecoloursoftherepairbreakermustberedandyellow.
Caution: Caution:
Caution:
Thepumpdoesnotpreventbackflowwhen
intentionallyorunintentionallystopped.Ifbackflow
maycauseahazardoussituationtoarise,precautions
mustbetakene.g.acheckvalvecanbeinstalledin
thesystemtopreventhazardoussituations.
Note: Note:
Note:
The3Astandardrequiresminimumclearance
betweenthelowestpartofthebase,pump,motoror
driveandforthefloortobenolessthan4in.(100
mm)
Step Step
Step2 2 2
Ensureatleast0.5m(1.6ft)clearancearoundthepump.
Step Step
Step3 3 3
Checkthattheflowdirectioniscorrect.
O:Outlet
I:Inlet
9

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Step Step
Step4 4 4
1.Ensurethatthepipelinesareroutedcorrectly.
2.Ensurethattheconnectionsaretight.
3.Remembersealrings
Step Step
Step5 5 5
A A
Avoid void voidstr str stress ess esson on onthe the thepump. pump. pump.
Piping Piping
Pipingsystem system systemmust must mustbe be beself self self- - -surpported. surpported. surpported.
Pay Pay
Payspecial special specialattention attention attentionto: to: to:
-Vibrations
-Thermalexpansionofthetubes
-Excessivewelding
-Overloadingofthepipelines
Exampleofpipingsystemself-supported.
10

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Step Step
Step6 6 6
Ensurecorrectalignmentofpumpinletandoutletwithpiping
system.
Alignmentcanbedonebyadjustingthepumplegs.
Centreofinletandoutlettobealignedwithcentreofpipingsystem.
11

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Nogapsbetweenconnectionsonpumpinletandinletpipe,andpumpoutletandoutletpipe.
Angelbetweenconnectionsonpumpinlerandinletpipe,pumpoutletandoutletpipenotallowed.
12

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Ensurecorrectaligmentofpumpcasingandpumpbackplate.Anglenotallowed.Alignmentcanbedonebyadjustingthe
pmplegs.
Ensurestudboltsincasingsarealignedwithholesinbackplate.
Note Note
Note
Incaseofshaftsealleakage,themediawilldripfromtheslotinthebottomoftheadaptor.Incaseofshaftsealleakage,Alfa
Lavalrecommendsputtingadriptrayunderneaththeslottocollecttheleakage.
13

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Step Step
Step7 7 7
Ifpumpisfittedwithdrainoption;
Nevershortcircuit.thedrainconnectionsasthiswillreducethe
airreleasecapacity.
Alwaysusetwodrainvalves.
Incorr Incorr
Incorrect ect ectCorr Corr
Correct ect ect
Step Step
Step8 8 8
Toensureoptimalfunctionoftheselfprimingcapacity,LKHPrime
mustbeinstalledinsuchawaythatensuresliquidisinthepump
onstart-upe.g.withaswanneckdesignasillustrated.
Note Note
Note
Maxrunningtimewhenreleasingaironlyshouldnotexceed15
min.
SminDmin
LKHPrimeP10
LKHPrimeP20200mm1.5m2”pipe
14

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!Alwayscheckthepumpbeforeoperation.
Seepreusecheckinsection3.3Preusecheck
Thepumpisheavy.
AlfaLavalthereforerecommendstheuseofaliftingcranewhenhandlingthepump.
Step Step
Step9 9 9
Installationguidelines
1.Suctionconsiderations
Installation-EnsurethesuctionlineisdesignedsothePrimePpumpisliquidfilledatstartup,eg.
swanneck.(seetableinStep6)
-Designsuctionlinewithslopedowntowardthepumptoavoidairentrapments
NPSH-EnsureNPSHa>NPSHrunderalldutyconditionsincludingalltemperatures
Airinclusions-Controlledstart/stopofpumpeg.LevelSwitch(LS)
-DonotstarttheLKHPrimePbeforetankbottomisliquidfilled
-StoptheLKHPrimePduringphasechanges
2.Generalpumpconsiderations
VFD-Minimumspeedforeffectiveairevacuationis2800RPM
-Airevacuationabilityimproveswithhigherspeed(Maxspeed3600RPM)
Pumpsizing-TheLKHPrimePmustbesizedforthespecificdutypoint
Note: Note:
Note:LKH LKH LKHPrime Prime PrimeP P Pis is isNOT NOT NOTa a aone one one- - -to to to- - -one one oner r replacement eplacement eplacementof of ofthe the theMR MR MRpump pump pump
3.Dischargeconsiderations
Installation-EnsureminimumlengthofverticalpipeaftertheLKHPrimeP(seetableinStep6)
Checkvalve-Placecheckvalveasfarawayfromthepumpaspossible
-Replacecheckvalvewithautomatedvalveifpossible
Pos
1Suctionline
2LKHPrimePPump
3Dischargeline
4Checkvalve
5Levelswitch
15

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Checkthedirectionofrotationoftheimpellerbeforeoperation.
Seetheindicationlabelonthepump.
3.3Pre-check
Step Step
Step1 1 1
Always Always
Alwaysremoveairscrewandimpellerbeforecheckingthe
directionofrotation.
Never Never
Neverstartthepumpiftheimpellerisfittedandthepumpcasing
isremoved.
1.Removeadaptershields(22)
2.Loosenunionsandremoverecirculationpipe(56)
3.Removeclamp(57)andfrontcover(60)
4.Removeairscrew(58)withaspanner.Counterholdwitha
screwdriver.(Seealsoinstructioninsection5.3)
5.nscrewcapnuts(24).Removewashers(24a)andpump
casing(29)
6.Removeimpeller(27).(Seealsoinstructioninsection5.3)
Step Step
Step2 2 2
1.Startandstopthemotormomentarily.
2.Ensurethatthedirectionofrotationofthestubshaft(7)is
anticlockwiseasviewedfromtheinletside.
Stubshaft
Step Step
Step3 3 3
Fitandtightentheimpeller(27).
16

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Checkthedirectionofrotationoftheimpellerbeforeoperation.
Seetheindicationlabelonthepump.
Step Step
Step4 4 4
1.Fitpumpcasing(29)andwashers(24a).Fitandtightencap
nuts(24).Torque=20Nm/15lbf-ft
2.Fitairscrew(58)andtightenwithaspanner(Torque=20Nm
(15lbf-ft))
3.FitfrontcoverO-ring(59)andfitandalignfrontcover(60).Fit
clampandtightenscrews(57)gently
4.Fitrecirculationspipe(56),alignfrontcover(60)andtighten
unions
5.Tightenclampscrews(57)
6.Fittheapaptorshields(22)
17

3Installation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Checkthedirectionofrotationoftheimpellerbeforeoperation.
Seetheindicationlabelonthepump.
3.4Recyclinginformation
npacking npacking
npacking
-Packingmaterialconsistsofwood,plastics,cardboardboxesandinsomecasesmetalstraps
-Woodandcardboardboxescanbereused,recycledorusedforenergyrecovery
-Plasticsshouldberecycledorburntatalicensedwasteincinerationplant
-Metalstrapsshouldbesentformaterialrecycling
Maintenance Maintenance
Maintenance
-Duringmaintenance,oilandwearingpartsinthemachinearereplaced
-Allmetalpartsshouldbesentformaterialrecycling
-Wornordefectiveelectronicpartsshouldbesenttoalicensedhandlerformaterialrecycling
-Oilandallnon-metalwearingpartsmustbedisposedofinaccordancewithlocalregulations
Scrapping Scrapping
Scrapping
-Attheendofuse,theequipmentmustberecycledaccordingtorelevantlocalregulations.Inadditiontotheequipmentitself,
anyhazardousresiduefromtheprocessliquidmustbetakenintoaccountandhandledinthenecessaryway.Whenindoubt,
orintheabsenceoflocalregulations,pleasecontactyourlocalAlfaLavalsalescompany.
18

4Operation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
4.1Operation/control
Step Step
Step1 1 1
Always Always
Alwaysreadthetechnicaldatacarefully.Seechapter6.1Technicaldata
CATION CATION
CATION
AlfaLavalcannotbeheldresponsibleforincorrectoperation/control.
Step Step
Step2 2 2
Never Never
Nevertouchthepumporpipelineswhenpumpinghotliquids
orwhensterilising.
Step Step
Step3 3 3
Never Never
Neverrunthepumpwhenboththesuctionsideandpressure
sideareblocked.
Risk Risk
Riskof of ofexplosion! explosion! explosion!
19

4Operation
Readtheinstructionscarefullyandpayspecialattentiontothewarnings!
Step Step
Step4 4 4
CATION CATION
CATION
Theshaftsealmustnotrundry.
CATION CATION
CATION
Never Never
Neverthrottletheinletside.
Do Do
Donot not not
allow allow
allowto to to
run run
rundry dry dry
Step Step
Step5 5 5
Double Double
Doublemechanical mechanical mechanicalshaft shaft shaftseal: seal: seal:
1.Connecttheinletoftheflushingliquidcorrectly.
(R1/8”)
2.Regulatethewatersupplycorrectly
O:Outlet
I:Inlet
Tmax=70°C
Pmax=5bar
(doublemechanicalseal)
Step Step
Step6 6 6
Contr Contr
Control: ol: ol:
Reducethecapacityandthepowerconsumptionbymeansof:
-Throttlingthepressuresideofthepump
-Reducingtheimpellerdiameter
-Reducingthespeedofthemotor(whennotreleasingair)
*Throttling!
20