Alfalaval LKHP User manual

Instruction Manual
LKHP Filtration Centrifugal Pump for High Inlet Pressure
TD 252-003
ESE01950-EN1 2011-01
Original manual

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-use check - pump without/with impeller screw ........................................... 9
3.4. Recycling information ............................................................................. 10
4. Operation ............................................................................................... 11
4.1. Operation/control ................................................................................. 11
4.2. Fault finding ....................................................................................... 13
4.3. Recommended cleaning ......................................................................... 14
5. Maintenance ........................................................................................... 15
5.1. General maintenance ............................................................................. 15
5.2. Cleaning Procedure ............................................................................... 16
5.3. Dismantling of pump/shaft seals ................................................................ 17
5.4. Assembly of pump/shaft seal .................................................................... 20
6. Technical data ......................................................................................... 23
6.1. Technical data ..................................................................................... 23
6.2. Relubrication intervals ............................................................................ 25
7. Parts list and service kits ............................................................................ 27
7.1. LKHP Filtration Centrifugal Pump for High Inlet Pressure ..................................... 27
7.2. LKHPF - Wet end ................................................................................. 28
7.3. LKHPF - Mortor dependent parts ............................................................... 30
7.4. LKHPF - Shaft seals .............................................................................. 32
3

1 EC Declaration of Conformity
The designated company
Alfa Laval
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declares that
Pump LKHP Filtration
Denomination Type Year
conforms with the following directives with amendments:
- Low Voltage Directive 2006/95/EC
- EMC Directive 2004/108/EC
- Machinery Directive 2006/42/EC
The technical construction file is retained at the above address
Manager, Product Center Fluid Handling Bjarne Søndergaard
Title Name
Alfa Laval Kolding
Company Signature
Designation
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are indicated 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

2Safety
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the pump are avoided.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 6 Technical data)
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 authorised personnel.
Always have the pump electrically connected by authorised personnel. (See the motor instructions)
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data)
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
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.
Always handle lye and acid with great care.
Maintenance:
Always read the technical data thoroughly. (See chapter 6 Technical data)
Never service the pump when it is hot.
The pump and the pipelines must never be pressurised when the pump is serviced.
Motors with grease nipples:
Remember that lubrication is according to 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 the pump in any way other than as 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 it’s upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
6

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The larger pumps sizes are very 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.
Check the delivery for:
1. Complete pump.
2. Delivery note.
3. Motor instructions.
Step 2
Remove possible packing materials from the inlet and the outlet.
Avoid damaging the inlet and the outlet.
Avoid damaging the connections for flushing liquid, if supplied.
TD 252-004
Remove
packing
materials!
Caution!
Step 3
Inspect the pump for visible transportation damage. Inspect!
TD 252-004
Step 4
Always remove the shroud, if fitted, before lifting the pump. Remove the shroud before lifting!
TD 252-005
7

3 Installation
Study the instructions carefully and pay special attention to the warnings! Always check the pump before operation.
- See the pre-use check in section 3.3 Pre-use check - pump without/with impeller screw.
The larger pumps 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.
(See chaper 6 Technical data)
Always have the pump electrically connected by
authorised personnel.
(see the motor instructions).
CAUTION
Alfa Laval cannot be held responsible for incorrect
installation.
Step 2
Ensure that there is sufficient clearance around the pump (min.
0.5 m) (1.64”).
TD 252-006
Step 3
Check that the flow direction is correct.
O: Outlet
I: Inlet
TD 252-007
I
O
Correct!
Step 4
1. Ensure that the pipelines are routed correctly.
2. Ensure that the connections are tight.
Remember seal rings!
TD 252-008 Few bends
Correct!
Step 5
Avoid stressing the pump.
Pay special attention to:
-Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
TD 252-009
8

3 Installation
Study the instructions carefully and pay special attention to the warnings!
LKH-5 to LKH-60 are supplied without impeller screw as standard but this can be supplied.
Check the direction of rotation of the impeller before operation.
- See the indication label on the pump.
3.3 Pre-use check - pump without/with impeller screw
Step 1
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.
1. Remove cap nuts (28), washers (29) and pump casing (45).
2. Remove impeller (39) (see also instruction in section 5.4
Assembly of pump/shaft seal).
TD 252-010
Step 2
1. Start and stop the motor momentarily.
2. Ensure that the direction of rotation of the stub shaft (9) is
anti-clockwise as viewed from the inlet side.
See the indication label!
Correct!
TD 252-011
Stub shaft
Step 3
Fit and tighten impeller (39).
TD 252-012
Step 4
1. Fit pump casing (45).
2. Fit washers (29) and cap nuts (28) and tighten.
Note: Cap nuts must be tightened according to torque values in
6 Technical data
TD 252-013
Step 1
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.
See the indication label!
Correct
TD 252-014 View from rear end of
motor
9

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 re-used, 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 disposed of in agreement with local regulations.
• Scrapping
- At the end of use, the equipment must be recycled according to the relevant, local regulations. Besides 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.
10

4Operation
Study the instructions carefully and pay special attention to the warnings!
Thepumpisfittedwithawarninglabel indicating correct throttling
4.1 Operation/control
Step 1
Always read the technical data thoroughly.
See chapter 6 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect
operation/control.
Step 2
Never touch the pump or the pipelines when pumping hot liquids
or when sterilising.
Burning danger!
TD 252-015
Step 3
Never run the pump with both the suction side and the pressure
side blocked.
Explosion danger!
TD 252-016
Step 4
CAUTION
The shaft seal must not run dry.
CAUTION
Never throttle the inlet side.
See the warning label!
Do not
run dry! Correct!
TD 252-017
Wrong
11

4Operation
Study the instructions carefully and pay special attention to the warnings!
The pump is fitted with a warning label indicating correct throttling
Step 5
Flushed shaft seal:
1. Connect the inlet of the flushing liquid correctly.
2. Regulate the water supply correctly.
3. Observe the steam data.
O: Free outlet
I: Inlet
Correct!
Tmax = 100˚ C
Pmax = 1 bar
I
O
TD 252-018
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.
TD 252-019
Throttling!
12

4Operation
Pay attention to possible faults.
Study the instructions carefully.
4.2 Fault finding
NOTE!
Study the maintenance instructions carefully before replacing worn parts. - See section 5.1 General maintenance
Problem Cause/result Remedy
Overloaded motor - Pumping of viscous liquids - Larger motor or smaller impeller
- Pumping of liquids with high density
- 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
- Increasing in noise level - Reduce the pressure drop before the
pump
- Reduce speed
Leaking shaft seal - Dry run (See 4.1 Operation/control) Replace:
All wearing parts (See 5.1 General
maintenance)
- Incorrect rubber grade If necessary:
- Change rubber grade
- Abrasive particles in the liquid - Select stationary and rotating seal ring
in Silicon Carbide/Silicon Carbide
Leaking seals Incorrect rubber grade Replace with seals of a different rubber
grade
13

4Operation
The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place.
Study 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.
Danger, caustic!
Always wear rubber
gloves!
Always wear protective
goggles!
Step 2
Never touch the pump or the pipelines when sterilizing.
Burning danger!
TD 252-015
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) +100 l (26.4 gal) = Cleaning agent.
NaOH water
2.2 l (0.6 gal) +100 l (26.4 gal) = Cleaning agent.
33%NaOH water
2. 0.5% by weight HNO3at 70°C (158°F).
0.7 l (0.2 gal) +100 l (26.4 gal) = Cleaning agent.
53% HNO3water
Step 4
1. Avoid excessive concentration of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the process
Sterilising of milk/viscous liquids
⇒Increase the cleaning flow!
Step 5
Always rinse well with clean water after using a cleaning agent.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Water Cleaning agent
14

5 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.
Check the pump for smooth operation after service.
5.1 General maintenance
Step 1
Always read the technical data thoroughly.
(See chaper 6 Technical data)
Always disconnect the power supply when servicing the pump.
NOTE
All scrap must be stored/discharged in accordance with current
rules/directives.
Step 2
Never service the pump when it is hot.
Burning danger!
TD 252-015
Step 3
Never service the pump with pump and pipelines under pressure.
CAUTION
Fit the electrical connections correctly if they have been removed
from the motor during service.
(see 3.3 Pre-use check - pump without/with impeller screw)
CAUTION
Pay special attention to the warnings!
TD 252-020
Atmospherie pressure
required!
Step 4
Recommended spare parts:
Service kits (see chapter 7 Parts list and service kits).
Order Service Kits from Service kits list (see chapter 7 Parts list
and service kits).
Ordering spare parts
Contact the Sales Department.
15

5 Maintenance
NOTE! Study the maintenance instructions carefully before replacing worn parts. - See section 5.1 General maintenance
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
planning of inspections
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
See section 6.2 Relubrication
intervals
Pre-use check
CAUTION!
Fit the electrical connections correctly if they have been removed from the motor during service. (See 3.3 Pre-use check -
pump without/with impeller screw).
Pay special attention to warnings!
1. Start and stop the motor momentarily
2. Ensure that the pump operates smoothly.
5.2 Cleaning Procedure
Cleaning procedure for Soiled Impeller Screw Tapped Hole:
1. Remove stub shaft (9) per section 5.3 of Service manual.
2. Submerge and soak Stub Shaft for 5 minutes in COP tank with 2% caustic wash
3. Scrub the blind tapped impeller screw hole vigorously by plunging a clean 1/2” diameter sanitary bristle pipe brush in and out
of the hole for two minutes while submerged.
4. Soak Stub Shaft (9) in acid sanitizer for 5 minutes, then scrub blind tapped hole as described in step 3 above.
5. Rinse well with clean water and blow-dry blind tapped hole with clean air.
6. Swab test the inside of the tapped hole to determine cleanliness.
7. Should the swab test fail, repeat steps 2 thru 6 above until swab test is passed.
Should swab testing continue to fail, or time is of the essence, install a new (spare) Stub Shaft (9).
16

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
5.3 Dismantling of pump/shaft seals
Step 1
1. Unscrew cap nuts (28) and remove washers (29) and pump
casing (45).
TD 252-021
Step 2
Remove screw (14) and safety guard (15).
TD 252-022
Step 3
Flushed shaft seal:
Unscrew fittings (23) using a spanner.
TD 252-023
Step 4
1. Remove impeller screw (41), if fitted, and pull off O-ring (42).
2. Remove impeller (39/40). If necessary, loosen the impeller by
knocking gently on the impeller vanes.
Counterhold
with a
screwdriver!
TD 252-024
If necessary!
Step 5
Pull out impeller (39/40) and the rotating part of the shaft seal.
TD 252-025
Step 6
Remove space ring (33) and the rotating part of the shaft seal from
impeller (39)/(40).
TD 252-026
17

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
Step 7
Separate rotating seal ring (34), quad rings (35, 38), support ring
(36), guide ring (37) and washer (37) from rotating seal housing (37).
TD 252-027
34
35
36
37
38
Step 8
1. Unscrew nuts (19) and remove washers (20) and back plate
(30).
2. Pull off joint ring (43) from the back plate.
TD 252-028
Step 9
1. Pull out stationary seal ring (32).
2. Remove O-ring (31) from the stationary seal ring.
TD 252-029
Step 10
Flushed shaft seal
1. Remove screws (22) and seal housing (21).
2. Pull out lip seal (24) and O-ring (26) from the seal housing.
3. Slideoffsleeve(27)fromstubshaft(9).
4. Remove O-ring (25) from the sleeve. TD 252-030
Step 11
1. Remove shroud (2).
2. Unscrew nuts (7) and remove washers (6), screws (18) and
adaptor (17).
TD 252-052
Step 12
1. Loosen screws(13).
2. Slide off stub shaft (9) together with compression rings (12a+b).
TD 252-053
18

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
Step 13
Separate screws (13), washers (13a) and compression rings
(12a+b).
TD 252-054
19

5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section.
Handle scrap correctly.
: Relates to the shaft seal.
5.4 Assembly of pump/shaft seal
Step 1
1. Fit compression rings (12a, 12b), washers (13a) and screws
(13) on stub shaft (9).
2. Slide the stub shaft onto the motor shaft.
3. Check the clearance between the end of the stub shaft and the
motor flange (10-20 mm) (0.39” - 0.78”).
TD 252-055
Step 2
1. Tighten screws (13) lightly and evenly.
2. Ensure that stub shaft (9) can be moved on the motor shaft.
TD 252-056
Step 3
Fit adaptor (17), screws (18), washers (6) and nuts (7) and tighten.
TD 252-057
TD 252-057
Step 4
Fit back plate (30), washers (20) and nuts (19) and tighten.
Tightening torques: See addendum.
TD 252-058
Step 5
Assemble the rotating part of the shaft seal as shown above.
CAUTION!
Ensure that the driver in the rotating seal housing enters the notch
in the rotating seal ring.
TD 252-035
34
35
36
37
38
Step 6
Fit the rotating part of the shaft seal and space ring (33) on impeller
(39/40).
TD 252-036
20