Alfalaval LKHex UltraPure 10 User manual

3001-0064
100000157-EN1 2018-02
Original manual
Instruction Manual
LKHex UltraPure Centrifugal Pump

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EU Declaration of Conformity ....................................................................... 4
1.1. ATEX Directive 2014/34/EU ...................................................................... 5
1.2. ATEX Marking ..................................................................................... 6
2. Safety .................................................................................................... 8
2.1. Important information ............................................................................. 8
2.2. Warning signs ..................................................................................... 8
2.3. Special conditions for safe use .................................................................. 9
2.4. Safety precautions ................................................................................ 12
3. Installation .............................................................................................. 14
3.1. Unpacking/delivery ............................................................................... 14
3.2. Installation ......................................................................................... 16
3.3. Pre-use check ..................................................................................... 18
3.4. Recycling information ............................................................................. 19
4. Operation ............................................................................................... 20
4.1. Important check and monitoring during operation ............................................ 20
4.2. Operating conditions ............................................................................. 21
4.3. Operation/control ................................................................................. 22
4.4. Trouble shooting .................................................................................. 24
4.5. Recommended cleaning ......................................................................... 25
5. Maintenance ........................................................................................... 26
5.1. General maintenance ............................................................................. 26
5.2. Dismantling of pump/shaft seals ................................................................ 28
5.3. Assembly of pump/single shaft seal ............................................................ 31
5.4. Assembly of pump/double mechanical shaft seal ............................................. 33
5.5. Adjustment of shaft ............................................................................... 36
6. Technical data ......................................................................................... 38
6.1. Technical data ..................................................................................... 38
6.2. Technical information and description of mechanical shaft seals ............................ 39
6.3. Torque specifications ............................................................................. 40
6.4.Weight (kg) ........................................................................................ 40
6.5. Noise emission .................................................................................... 41
6.6. Relubrication intervals ............................................................................ 42
7. Parts list ................................................................................................ 43
7.1. Drawing LKHex UltraPure -10, -20, -25, -35, -40, -45, -60, -70 ............................ 43
7.2. LKHex UltraPure - Product wetted parts ....................................................... 44
7.3. LKHex UltraPure - Motor dependent parts ..................................................... 46
7.4. LKHex UltraPure - Shaft seal .................................................................... 48
3

1 EU Declaration of Conformity
Alfa Laval certificate no.: 9612-9609-01 X
This declaration of conformity is issue under sole responsibility of the manufacturer:
Alfa Laval Kolding A/S
Company Name
Albuen 31, 6000 Kolding,
Denmark
Address
[phone]
Phone No.
Equipment covered by this declaration of conformity:
Pump
Designation
LKHex UP-10, LKHex UP-20, LKHex UP-25, LKHex UP-35, LKHex UP-40, LKHex UP-45, LKHex UP-60, LKHex UP-70
Type
From serial number 212.000 to 1.000.000
is in conformity with the requirements of the following directives:
2006/42/EC Machinery Directive
2014/34/EU Equipment Explosive Atmospheres (ATEX)
Pump Marking Options:
For specific marking see pump name plate and refer to “Special Conditions for Safe Use” in instruction manual.
II 2 G
Ex h IIB T4 Gb Ta -20C to +35C
II 2 G
Ex h IIB T4 Gb
II 2 G
Ex h IIB T3 Gb
For ATEX directive 2014/34/EU the following harmonized standards EN 80079-36:2016 and EN 80079-37:2016 for none
electrical equipment have been applied.
ATEX directive 2014/34/EU conformity for the motor is covered by the relevant EU Type examination certificate and declaration
supplied by the manufacturer.
The Pump Technical file is stored with: Teknologisk Institut, Kongsvang Allé 29, 8000 Aarhus C, Denmark
Notified Body no.: 0396
Archive no.: 2018-1-0276A
The person authorized to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name Signature
Alfa Laval Kolding, Albuen 31, DK 6000 Kolding 2018-02-05
Place Date
4

1 EU Declaration of Conformity
1.1 ATEX Directive 2014/34/EU
ATEX Directive 2014/34/EU
The ATEX Directive 2014/34/EU covers equipment and protective systems that will be used in areas endangered by potentially
explosive atmospheres created by the presence of flammable gases, vapours and dusts. Centrifugal pumps supplied with
an ATEX symbol are classified for use in potentially explosive atmospheres under ATEX Directive 2014/34/EU Group II,
Categories 2 and 3.
Technical File Ref: LKHex UltraPure - Document reference no. 9612-9609-01.
Equipment Group and Category: Group II category 2 G (zone 1)
Standards used: EN 80079-36:2016, EN 80079-37:2016
5

1 EU Declaration of Conformity
1.2 ATEX Marking
Name plate example:
Pump Type
Serial No.
Alfa Laval, Albuen 31, Kolding, DK-6000
LKHex UP-20
Specification
123456 Year 2018
II 2 G
Ex h IIB T4 Gb Ta -20C to +35C
Shroud not allowed
Dia:163 11.0kW 50Hz SSS
A
B
C
D
Manufacturer:
A163 11.0kW 50Hz SSS
Shaft seal type (single shaft seal)
Max power output at 50Hz
Impeller diameter (Ø163)
BII 2 G
ATEX marking - directve part
CEx h IIB T4 Gb Ta -20C to +35C
Ambient temperature limit. See instruction manual
”Special Conditions for Safe Use” table A
ATEX marking - standard part
DShroud not allowed
Defines if pump can be with or without shroud.
See instruction manual “Special Conditions for Safe use” table A
6

1 EU Declaration of Conformity
Name plate position
3001-0063
See marking options in chapter 2.3 Special conditions for safe use , table A.
7

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:
8

2 Safety
All warnings in the manual are summarised in this section.
Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided.
2.3 Special conditions for safe use
General warnings.
Always read chapter 4.2 Operating conditions.
Never run the pump with neither the suction side nor the pressure side blocked.
Always ensure that the pump is liquid filled when operating, unless a doubled mechanical seal is fitted (See table C).
Always ensure that the pump is liquid filled if the process media is flammable.
Never mount shroud on the pump if the name plate states "shroud not allowed".
Always stop the pump if
- operating outside the given limits of the process media temperature or flow rate (See table A and B).
- operating outside the given limits of the flush media temperature or flow rate (See table C).
-Note it must be ensured that the flow and temperature limits for the process media or flush media are maintained when the
pump is operating. If this cannot be ensured in any other way, the flow and temperature should be continuously monitored.
Note In case of seal failure, leakage may occur. If this can lead to hazardous situations, the risk must be evaluated and
necessary precautions must be taken. (See chapter 6.2 Technical information and description of mechanical shaft seals).
Note the motor is a separate certified ATEX product and covered by EU-type examination certificate and must be handled
according to the specifications in the motor instruction manual.
Safety critical limitations for specific ATEX markings.
Table A
Pump marking options Ambient temperature Critical temperature range of
process media
II 2 G
Ex h IIB T4 Gb Ta -20C to +35C
-20°C to +35°C
(Shroud allowed) *3
II 2 G
Ex h IIB T4 Gb
-20°C to +40°C
(Shroud NOT allowed)
-10°C to 100°C *1&2
II 2 G
Ex h IIB T3 Gb
-20°C to +40°C
(Shroud allowed) -10°C to 140°C *1&2
*1 See table B for position of temperature sensor and min. flow rates.
*2 “b1” ignition control is used, see details in section below “b1 control system requirements”.
*3 For pumps with temperature class T4 and with 18,5kW motors or larger, shroud is not allowed (independent of ambient
temperature).
Note For T4 applications the pump casing and seal housing can be sterilized to max 125oC when the pump is NOT operating.
Note Ensure that the chosen elastomer is compatible with the process media and the media temperature (see chapter
4.2 for more information).
Note The LKHex UltraPure can only be marked for category 2G but can be used for 3G applications also.
9

2 Safety
All warnings in the manual are summarised in this section.
Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided.
Requirements for measurements on the process media
There are two principles of temperature measurements of the process media:
A. Temperature is measured on the pump outlet side (S1). No equipment with cooling effect on the process media is allowed
between pump and sensor.
B. Temperature is measured somewhere on the pump inlet side (S2). No heat generating equipment is allowed between the
temperature sensor and the pump.
3001-0062
S1
S2
Table B Measurements on process media
Temperature
sensor position Model Min. flow [m3/h] Max. distance
to outlet [m]
LKHex UP 10-70 0,5 0,5
LKHex UP 10-60 110
S1 (outlet side) LKHex UP 70 5 10
LKHex UP 10-60 1
S2 (inlet side) LKHex UP 70 5Anywhere on
inlet side
Requirements for measurements on the flush media (double mechanical shaft seal)
Table C Flush media limitations
Max. temperature 100°C
MIn. flow rate 30 l/h
Max. pressure 5 bar
Note: Flush media temperature must be measured no more than 2m away from the flush housing outlet.
Pumps mounted with double mechanical shaft seals can operate without the pump casing being liquid filled at all times since the
seal faces are lubricated and cooled by the flush media.
10

2 Safety
All warnings in the manual are summarised in this section.
Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided.
“b1” control system requirements
Measurement system shall be chosen according to EN-ISO 80079-37.
Always test and validate the control system before production start-up.
The ignition protection system performance requirements:
Temperatures:
-+/-2°C
- 30s reaction time
Flow:
-+/-10%
- 30s reaction time
The demand for the ignition protection system b1 must be according to ISO 13849-1 PL c cat. 2 or IEC 61508 SIL 1 and
must be calibrated and functionally tested on a yearly basis.
11

2 Safety
2.4 Safety precautions
General considerations
To prevent hazardous reactions between the processed fluid and the materials of construction, the materials of construction
must be suitable for the application.
The auxiliary equipment chosen for the application must be suitable.
Education
Personnel installing, operating or carrying out maintenance on the pump or any sub-component must have the necessary
knowledge about the LKHex UltraPure pump range. Necessary knowledge includes the understanding of:
- Function of the pump, motor and shaft seal.
- Maintenance/service of the pump unit, motor and shaft seal.
- Operational limits for the LKHex UltraPure pump range.
- Safety instructions.
Installation
Always read chapter 3 regarding installation carefully before installing the pump unit.
Always ensure that the pump unit is suitable for the application and will stay within the specifications in chapter 4.2
Operating conditions during normal operation.
Always read the technical data thoroughly. (See chapter 6 Technical data.)
Always use a lifting crane when handling the pump. !
Always design the process system in a way so pressure shocks or over pressure is avoided.
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)
Never start the pump if the impeller is fitted and the pump casing is removed.
Operation
Always read the chapter 4 Operation before the pump is started.
Always ensure that the pump is operated within the specifications given in chapter 4.2 Operating conditions.
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 the Alfa Laval pump selection program.
Never restart the pump automatically after a system lockout. At restart, it must be ensured that the pump is running within
the specifications given in chapter 4.2 Operating conditions.
The Alfa Laval pump selection program can be acquired from your local Alfa Laval sales company.
12

2 Safety
Maintenance
Always read the chapter 5 Maintenance before servicing the pump.
Always make sure that the specifications in chapter 4 Operation are met before the pump is put back into operation.
Always refer to the pump serial no. on the name plate when ordering spare parts to ensure correct spares.
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never service the pump when it is hot.
Never service the pump if pressurised.
Always check for any abnormal sounds or running behaviors when starting up the pump after maintenance.
Always useAlfaLavalgenuinespareparts.
Motors with grease nipples:
Always re-lubricate the motor according to the intervals specified on the motor name plate, see also 6 Technical data
for relubrication intervals.
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 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 its upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
13

3 Installation
3.1 Unpacking/delivery
Step 1
Always use a lifting crane when handling the pump (see 6
Technical data).
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
WARNING
Be aware that certain pump configurations can tilt, and therefore
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.
4. Instructions for flushing set, IF ORDERED!
Step 2
Remove any packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
3007-0090
Remove
packing
materials!
Step 3
Inspect the pump for visible transport damage. Inspection!
3007-0090
14

3 Installation
Step 4
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before lifting!
3007-0092
Step 5
ONLY LKH UltraPure-60 and LKH UltraPure-70 Do NOT use eyebolt in casing to lift the pump. The
eyebolt is for casing removal only.
3007-0093
15

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 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.
Always check the nameplate and make sure that the pump is labelled according to the particular application where it is going
to be used.
Always ensure that an ATEX-compliant protection system is installed, in order to prevent the pump from operating under
abnormal conditions. The system must comply with EN ISO 80079-37:2016 or similar standards.
Always use ATEX-compliant installation material.
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 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 can cause any hazardous
situations precautions must be taken e.g. check valve to be installed in the system to prevent the problem described above.
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 inch. (100mm)
Step 2
Ensure at least 0.5m (1.6 ft) clearance around the pump.
3007-0094
16

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 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.
O: Outlet
I: Inlet
3007-0007
O
I

Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
3007-0008

Few bends
Correct
Step 5
Avoid stress on the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
- Piping system must be self-supported.
3007-0009
!
Note
In the event of leakage at the shaft seal, the medium will drip from the slot into the bottom of the adapter. In the instance, Alfa
Laval recommends placing a drip tray underneath the slot to collect the liquid.
17

3 Installation
Read the instructions carefully and pay special attention to the warnings!
LKH UltraPure is not supplied with an 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.
3.3 Pre-use check
Step 1
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.
See the indication
label!
3007-0014

View from rear end
of motor
18

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 accordance with local regulations.
• Scrapping
- At end of use, the equipment must 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 your local Alfa Laval sales company.
19

4Operation
Read the instructions carefully and pay special attention to the warnings!
4.1 Important check and monitoring during operation
Daily checks
- Shaft seal (SSS and DMS)
If leakage from the shaft seal can lead to dangerous situations, daily visual inspection for leakage is recommended.
- If leakage is detected the risk should be evaluated and maintenance of the seal should be planned accordingly.
Other checks
Motor
- The bearing life is heavily dependent on the operating condition of the pump i.e. pressure, ambient temperature, motor
load and pressure variations.
- The motor should be serviced according to the guidelines in the motor instruction manual
- The motor should be relubricated with the intervals given in chapter 6.6 “Reblurication intervals”.
In order to detect motor bearing failure, the condition of the bearings must be monitored regularly.
It is recommended that the condition of the bearings is checked every 2000 hours of operation.
The condition of the bearings can be be monitored in several ways eg. by means of vibration analysis (shock pulse
measurements).
After checking the bearing condition, it must be evaluated if it is OK to continue or else maintenance of the bearings must be
planned accordingly.
20