Alfalaval LKH UltraPure User manual

IM70831-EN2 2005-06
LKH UltraPure Centrifugal Pump
Instruction Manual
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Alfa Laval
Company Name
Bjarne Søndergaard
Declaration of Conformity
The designating company
Designation
is in conformity with the following directives with amendments:
- Low Voltage Directive 73/23/EEC
- EMC Directive 89/336/EEC
- Machinery Directive 98/37/EEC
hereby declare that
Denomination Type Year
Address
Phone No.
Name
Title
Company Signature
Vice President, R & D
Alfa Laval
Albuen 31, DK-6000 Kolding, Denmark
[phone]
Centrifugal Pump LKH UltraPure
3
2004
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The information contained herein is correct at the time of issue but may be subject to change without prior notice.
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1. Safety.....................................................................................................6
1.1 Important Information........................................................................6
1.2 Warning Signs...................................................................................6
1.3 Safety Precautions............................................................................7
2. Installation .............................................................................................8
2.1 Unpacking/Delivery...........................................................................8
2.2 Installation.........................................................................................9
2.3 Pre-use check - Pump without/with impeller screw.........................10
3. Operation............................................................................................. 11
3.1 Operation/Control...........................................................................11
3.2 Fault finding....................................................................................12
3.3 Recommended Cleaning ................................................................13
4. Maintenance........................................................................................ 14
4.1 General Maintenance......................................................................14
4.2 Dismantling of pump/shaft seals .....................................................16
4.3 Assembly of pump/single shaft seal................................................18
4.4 Assembly of pump/double mechanical shaft seal............................20
4.5 Assembly of flushing set - if not supplied with pump.......................22
4.6 Adjustment of shaft ........................................................................23
5. Technical data......................................................................................24
5.1 Technical data.................................................................................24
5.2 Relubrication Intervals.....................................................................25
6. Parts list and Service Kits..................................................................27
6.1 LKH UltraPure-10, -20, -25, -35, -40..............................................28
6.2 LKH UltraPure-10 ...........................................................................28
6.3 LKH UltraPure-20 ...........................................................................30
6.4 LKH UltraPure-25, -35,...................................................................32
6.5 LKH UltraPure-40 ...........................................................................34
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1. Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the pump!
WARNING!
Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION!
Indicates that special procedures must be followed to avoid damage to the pump.
NOTE!
Indicates important information to simplify or clarify practices.
1.1 Important Information
1.2 Warning Signs
General warning.
Dangerous electrical voltage.
Caustic agents.
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Installation:
Always read the technical data thoroughly. (See chapter 5).
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 authorized personnel. (See the motor instruc-
tions).
Operation:
Always read the technical data thoroughly. (See chapter 5).
Never touch the pump or the pipelines when pumping hot liquids or when sterilizing.
Never run the pump with both the suction side and the pressure side blocked.
Always handle lye and acid with great care.
Maintenance:
Always read the technical data thoroughly. (See chapter 5).
- Never service the pump when it is hot.
- Never service the pump with pump and pipelines under pressure.
Motor with grease nipples:
Remember lubrication according to information plate/label on the motor.
Always disconnect the power supply when servicing the pump.
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided.
1. Safety 1.3 Safety Precautions
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2. Installation
2.1 Unpacking/Delivery
Remove packing materials!
Step 1
Always use a lifting crane when handling the pump
(see technical data).
CAUTION!
Alfa Laval cannot be held responsible for incorrect
unpacking.
The instruction manual is part of the delivery. Study the instructions carefully.
The large pump sizes are very heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
4. Instructions for flushing set, IF ORDERED!
Inspection!Step 3
Inspect the pump for visible transport damages.
Step 2
Remove possible packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Step 4
Avoid damaging the connections for flushing liquid, if
supplied.
Step 5
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before lifting!
Caution!
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2. Installation 2.2 Installation
Step 2
Ensure that there is sufficient clearance around the pump
(min. 0.5 m) (1.6 ft).
Step 1
Always read the technical data thoroughly (see chapter 5).
Always use a lifting crane when handling the pump (see technical data).
Always have the pump electrically connected by authorized personnel (see the motor instructions).
CAUTION!
Alfa Laval cannot be held responsible for incorrect installation.
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See pre-use check in section 2.3.
The large pump sizes are very heavy.
Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
Step 3
Check that the flow direction is correct.
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Step 5
Avoid stressing the pump.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
O: Outlet
I: Inlet
Correct!
Remember
seal rings!
Correct!
Few bends!
Risk of damage!
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2. Installation
2.3 Pre-use check - Pump without/with impeller screw
Study the instructions carefully and pay special attention to the warnings!
LKH UltraPure is 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.
See the indication label!
Correct!
Stub shaft
Step 5 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.
Step 1
- Always remove the impeller before checking the direction of ro-
tation.
- Never start the pump if the impeller is fitted and the pump casing
is removed.
1. Remove cap nuts (24), washers (24a) and pump casing (29).
2. Remove impeller (27) (see also section 4.1).
Correct!
View from rear end
of the motor
See the indication
label!
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.
Step 3
Fit and tighten impeller (27).
Step 4
1. Fit pump casing (29).
2. Fit washers (24a) and tighten cap nuts (24).
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3. Operation 3.1 Operation/Control
Study the instructions carefully and pay special attention to the warnings!
The pump is fitted with a warning label indicating correct throttling.
Burning
danger!
Correct!
Step 1
Always read the technical data thoroughly (see chapter 5).
CAUTION!
Alfa Laval cannot be held responsible for incorrect operation/con-
trol.
Explosion
danger!
See the warning label!
Do not
run dry!
Throttling!
Step 2
Never touch the pump or the pipelines when pumping hot liquids
or when sterilizing.
Step 3
Never run the pump with both the suction side and the pressure
side blocked.
Step 4
CAUTION!
- The shaft seal must not run dry.
- Never throttle the inlet side.
Step 5
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.
Wrong!
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Problem
Overloaded motor
- Damage
- Pressure reduction
(sometimes to zero)
- Increased noise level
Leaking shaft seal
Leaking seals
Cause/result
- Pumping of viscous liquids
- Pumping of liquids with high density
- Low outlet pressure (counter
pressure)
- Lamination of precipitates from the
liquid
- Low inlet pressure
- High liquid temperature
- Incorrect rubber grade
- Abrasive particles in the liquid
- Dry run
(See section 3.1)
Incorrect rubber grade
Repair
- Larger motor
- Smaller impeller
- Higher counter pressure
(throttling)
- Frequent cleaning
- Increasing of the inlet pressure
- Reducing the liquid temperature
- Reducing the pressure drop
before the pump
- Reducing the speed
Replace:
All wearing parts (See chapter 4)
If necessary:
- Select a different rubber grade
- Select stationary and rotating seal
ring in Silicon Carbide/Silicon Car-
bide (abrasive particles)
Replace with seals of a different
rubber grade
3. Operation
3.2 Fault finding
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See section 4.1!
Pay attention to possible faults.
Study the instructions carefully.
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Step 3
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70o C (158°F).
1 kg (2.2 lbs) + 100 l (26.4 gal) = Cleaning agent.
NaOH water
2.2 l (0.58 gal) + 100 l (26.4 gal) = Cleaning agent.
33%NaOH water
Always rinse!
Burning danger!
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Pay special attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
Step 1
Always handle lye and acid with great care.
3.3 Recommended Cleaning
Step 2
Never touch the pump or the pipelines when sterilizing.
Step 5
Always rinse well with clean water after the cleaning.
CAUTION!
Thecleaningagentsmustbe stored/disposedofin accordance
with current rules/directives.
3. Operation
Always use Always use
rubber gloves! protective goggles!
Caustic danger!
Water Cleaning
agent
Step 4
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!
2. 0.5% by weight HNO3at 70o C (158°F).
0.7 l (0.18 gal) + 100 l (26.4 gal) = Cleaning agent.
53% HNO3water
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4. Maintenance
4.1 General 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.
See separate instructions for flushing set - if ordered.
Step 3
Never service the pump with pump and pipelines under pressure.
Step 1
Always read the technical data thoroughly (see chapter 5).
Always disconnect the power supply when servicing the pump.
NOTE!
All scrap must be stored/disposed of in accordance with current rules/directives.
Burning danger!
Atmospheric pressure
required!
Step 4
CAUTION!
Fit the electrical connections correctly if they have been removed
from the motor during service (see pre-use check in section 2.3).
Pay special attention to the warnings!
Step 2
Never service the pump when it is hot.
Step 5
Recommended spare parts:
Service kits (see chapter 6).
Order service kits from the service kits list (see chapter 6).
Ordering spare parts:
- Contact the Sales Department.
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Preventive maintenance
Maintenance after leakage
(leakage normally starts
slowly)
Planned maintenance
Lubrication
Shaft seal
Replace after 12 months:
(one-shift)
Complete shaft seal
Replace by the end of
the day:
Complete shaft seal
- 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
Before fitting
Lubricate the Quad-/O-
rings with silicone grease
or silicone oil
Rubber seals
Replace when replacing the
shaft seal
Replace when replacing the
shaft seal
Replace when replacing the
shaft seal
Before fitting
Silicone grease or silicone
oil
Motor bearings
Yearly inspection is
recommended.
- Replace complete bearing
if worn.
- Ensure that the bearing is
axially locked (See motor
instructions)
See“Relubrication Intervals”,
section 5.2
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.
4.1 General Maintenance
4. Maintenance
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service.
(See pre-use check in section 2.3).
Pay special attention to the warnings!
1. Start and stop the motor momentarily.
2. Ensure that the pump operates smoothly.
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4. Maintenance
4.2 Dismantling of pump/shaft seals
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
Step 3
Double mechanical shaft seal:
Unscrew tubes (42) using a spanner.
Step 2
Unscrew cap nuts (24) and remove washers (24a) and pump
casing (29).
Counterhold with a
screwdriver!
Step 6
1. Pull off the O-ring (26) from back plate (25).
2. Unscrew nuts (20) and remove washers (21) and
the back plate.
If necessary!
Step 5
1. Remove impeller screw (36), if fitted.
2. Remove impeller (27/37). If necessary, loosen the
impeller by tapping gently on the impeller vanes.
3. Remove the O-ring (38) from the impeller, if fitted.
Step 4
Remove screw (23) and safety guard (22).
Step 1
Flushing set for double mechanical shaft seal:
1. Remove flow meter and pressure gauge.
2. Remove upper tube.
3. Remove flushing set (54) from pump casing (29) and
lower tube (42) and remove lower tube.
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4. Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
4.2 Dismantling of pump/shaft seals
Use the tool supplied!
Left hand thread!
Step 7
1. Remove the stationary seal ring (11).
2. Remove the O-ring (12) from back plate (25).
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).
Step 10
Single shaft seal:
1. Remove the complete shaft seal from stub shaft (7).
2. Remove spring (13) and rotating seal ring (14) from the drive
ring (10).
Step 9
Double mechanical shaft seal:
1. Remove stationary seal ring (51) from seal housing
(40a/40b).
2. Remove O-ring (50) from stationary seal ring (51).
3. Remove O-ring (44) from seal housing (40a/40b).
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4. Maintenance
4.3 Assembly of pump/single shaft seal

Step 2
1. Refit spring (13) on rotating seal ring (14).
2. Fit the spring and the rotating seal ring on
drive ring (10).
CAUTION!
Ensure that the driver on the drive ring enters the notch in the
rotating seal ring.
Step 1
Remove spring (13).
NOTE!
Make sure that O-ring (15) has max. clearance from the sealing
surface.
Step 3
Fit the complete shaft seal on stub shaft (7).
NOTE!
Make sure that connex pin (8) on the stub shaft enters the notch
in drive ring (10).
Step 6
Lubricate O-ring (26) and slide it onto back plate (25).
Step 5
1. Clean the sealing surfaces with contact cleaner before fitting
back plate (25).
2. Carefully guide the back plate onto adaptor (16).
3. Fit washers (21) and nuts (20).




Step 4
1. Fit O-ring (12) on stationary seal ring (11) and lubricate.
2. Screw the stationary seal ring into back plate (25).
CAUTION!
Only tighten by hand to avoid deforming the stationary seal ring
(max. 7 Nm).
Use the tool
supplied!
Left hand
thread!
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
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4. Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
Step 8
Fit safety guard (22) and screw (23) and tighten.
Step 9
1. Fit pump casing (29), washers (24a) and cap nuts (24).
2. Adjust pump casing to the right position.
3. Tighten nuts (20) for back plate (25) and tighten cap
nuts (24).
Step 7
1. Lubricate O-ring (38) and fit it in impeller (37), if impeller
screw is used.
2. Lubricate the impeller hub with silicone grease or oil.
3. Screw the impeller (27/37) onto stub shaft (7).
4. Fit impeller screw (36) and tighten, if used.
4.3 Assembly of pump/single shaft seal
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4. Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Lubricate the rubber seals before fitting them.
 : Relates to the shaft seal.
4.4 Assembly of pump/double mechanical shaft seal
Step 1
1. Fit O-rings (15) in rotating seal rings (14).
2. Fit spring (13) on one of the rotating seal rings (14) and place the drive ring (52) in between.
3. Fit the second rotating seal ring (14) on the other end of the spring.
Note:
Ensure that both drive pins on the drive ring enters the notches in rotating seal rings.
4. Place the parts on the stationary seal ring fitted in back plate (25).
Step 2
1. Lubricate O-ring (44) and slide onto seal housing (40a).
2. Lubricate O-ring (50) and fit on stationary seal ring (51)
and fit this in the seal housing.
Step 3
1. Clean the sealing surfaces with contact cleaner.
2. Fit seal housing (40a) on the back plate (25) and tighten
screws (41).
Step 5
Lubricate O-ring (26) and slide it onto back plate (25).
Step 6
1. Lubricate O-ring (38) and fit it in impeller (37), if
impeller screw is used.
2. Lubricate the impeller hub with silicone grease
or oil.
3. Screw impeller (27/37) onto stub shaft (7).
4. Fit impeller screw (36) and tighten, if used.
Step 4
1. To enable fitting back plate (25) with the shaft seal
remove connex pin (8) from stub shaft (7) (if fitted).
2. Carefully guide the back plate onto adaptor (16).
3. Fit washers (21) and nuts (20).


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