Alfalaval SRU series User manual

ESE00693-EN14 2017-09
Original manual
Instruction Manual
Rotary Lobe Pumps - SRU Range

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. General information ................................................................................... 5
2.1. General information ............................................................................... 5
3. Safety .................................................................................................... 6
3.1. Important information ............................................................................. 6
3.2. Warning signs ..................................................................................... 6
3.3. Safety precautions ................................................................................ 7
4. Installation .............................................................................................. 8
4.1. Unpacking, handling and storage ............................................................... 8
4.2. System design and installation .................................................................. 9
4.3. Flushing seal arrangement and pre-start up checks .......................................... 13
4.4. Recycling information ............................................................................. 14
5. Maintenance ........................................................................................... 15
5.1. Cleaning in place (CIP) ........................................................................... 15
5.2. Maintenance schedule ........................................................................... 16
5.3. Dismantling ........................................................................................ 17
5.4. Assembly .......................................................................................... 20
5.5. Primary seals removal and fitting ................................................................ 27
5.6. Pressure relief valve ............................................................................... 33
5.7. Heating/Cooling devices ......................................................................... 35
5.8. Troubleshooting ................................................................................... 36
6. Technical data ......................................................................................... 37
6.1. Technical data ..................................................................................... 37
6.2. Pumphead Clearance information .............................................................. 40
7. Parts list ................................................................................................ 44
7.1. SRU1 Pump Range ............................................................................... 44
7.2. SRU2 Pump Range ............................................................................... 46
7.3. SRU3 Pump Range ............................................................................... 48
7.4. SRU4 Pump Range ............................................................................... 50
7.5. SRU5 Pump Range ............................................................................... 52
7.6. SRU6 Pump Range ............................................................................... 54
3

1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Eastbourne, Alfa Laval Ltd
Company Name
Birch Road, Eastbourne, East Sussex BN23 6PQ
Address
[phone]
Phone No.
hereby declare that
Pump
Designation
SRU1, SRU2, SRU3, SRU4. SRU5. SRU6
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 2013-12-03
Place Date Signature
4

2 General information
2.1 General information
The SRU pump supplied is a positive displacement rotary lobe pump; it may be supplied with or without a drive unit (see
drawing). The drawing shown indicates various parts of the pump unit.
The SRU range has a universal gearbox design which enables the flexibility of mounting pumps with the inlet and outlet ports
in either a vertical or horizontal plane. The port orientation, vertical or horizontal, may be changed by moving one of two
available bolt-on feet on the gearbox. Port orientation should be specified when ordering, but the alternative foot design
allows pumps that are already installed being changed should the need arise.
Drawing shows only mounted unit Drive unit
Gearbox
Product seal area
Ports
Rotorcase Coupling guard (encloses coupling)
Rotorcase cover
TD 243-003_1
Baseplate fixing holes
Pump duty conditions
The pump should only be used for the duty for which it has been specified. The operating pressure, speed and temperature
limits have been selected at the time of order and MUST NOT be exceeded. These details are stated on the original order
documentation and if not available may be obtained from your supplier quoting pump model and serial number.
Noise levels
Under certain operating conditions pumps and/or drives and/or the systems within which they are installed can produce sound
pressure levels in excess of 80dB[A]. When necessary, protection against noise should be taken.
External Cleaning
Use cleaning fluids below PH 8. Cleaning fluids above PH 8 may cause some paint discolouration.
5

3 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
3.1 Important information
Always read the manual before using the pump!
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.
3.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
Not applicable for Atex applications
6

3 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
3.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never start in the wrong direction of rotation with liquid in the pump.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
Always have the pump electrically connected by authorized personnel. (see the motor instructions supplied with
the drive unit)
Operation:
Always read the technical data thoroughly. (See chapter 6 Technical data) !
Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
Never stand on the pump or pipelines.
Never run the pump with both the suction side and the pressure side blocked.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
Never run the pump unless fully assembled, i.e. pump head must not be removed from gearcase.
Only handle toxic and acidic liquids in accordance with the manufacturers instructions and recommendations.
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.
Never put your hands or fingers inside the port connections or anywhere close to rotating parts.
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 it’s upright position
Always ensure that the unit is securely fixed during transportation
Always use original packaging or similar during transportation
7

4 Installation
4.1 Unpacking, handling and storage
Step 1
Refer to the pump weights guide (6 Technical data) before selecting and using any lifting gear. The drawings show how
the pump should be lifted.
Ensure that lifting equipment is correctly rated and used within these limits.
Pump with drive unit Bareshaft pump
Step 2
On receipt always:
- Check the delivery note against the goods received.
- If motorised, check that the drive instructions are available.
- Be careful not to discard any manuals that may be enclosed with the packaging.
- Inspect the packing for signs of damage in transit.
- Carefully remove the packing away from the pump.
- Inspect the pump for any visible signs of damage.
- Clean away the packing from the pump port connections.
- Report any damage immediately to the carrier.
Step 3
After receipt and inspection, if the pump is not to be installed immediately, the pump should be repacked and placed in
suitable storage. The following points should be noted:
- Plastic or gasket type port covers should be left in place.
- Pumps received wrapped with corrosion inhibiting treatment material should have wrapping replaced.
- A clean, dry storage location free from vibration should be selected. If a moist or dusty atmosphere is used for storage,
further protect the pump or unit with a suitable cover.
- Rotate the pump/pump unit by hand weekly, to prevent bearing damage.
- All associated ancillary equipment should be treated similarly.
8

4 Installation
To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the
following should be taken into consideration.
4.2 System design and installation
Design: Discharge line
Plan view Suction line
Manifold suction/Common Line
- Confirm the Net Positive Suction Head (NPSH) available
from the system exceeds the NPSH required by the pump,
as this is crucial for ensuring the smooth operation of the
pump and preventing cavitation.
- Avoid suction lifts and manifold/common suction lines for
two pumps running in parallel, as this may cause vibration
or cavitation.
- Protect the pump against blockage from hard solid objects
e.g. nuts, bolts welding slag etc. Also protect the pump
from accidental operation against a closed valve by using
relief valves, pressure switches or current limiting devices.
- Fit suction and discharge monitor points for diagnostic
purposes.
- Fit valves, if two pumps are to be used on manifold/common
discharge lines.
- Make the necessary piping arrangements if flushing is
required for the seal or if a media is required for heating/
cooling jackets and saddles.
- Allow at least 1 m for pump access/maintenance all around
the pump.
- Do not subject rotary lobe pumps to rapid temperature
changes, as pump seizure can result from thermal shock.
Pipework:
All pipework must be supported. The pump must not be allowed to support any of the pipework weight beyond the limits
set as shown in the following table.
Remember:
Pipework supports must also support the weight of the product
being pumped.
- Design short straight suction lines to reduce friction losses
in the pipework thereby improving the NPSH available from
the system.
- Avoid bends, tees and any restrictions close to either
suction or discharge side of pump. Use long radius bends
wherever possible.
- Provide isolating valves on each side of the pump when
necessary.
- Keep pipework horizontal where applicable to reduce air
locks. Include eccentric reducers on suction lines.
TD 243-089
X
Y
Z
9

4 Installation
To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the
following should be taken into consideration.
Table of Maximum Forces and Moments
Forces Moments
Pump
Model Units FZ FY FX EF Units MZ MY MX EM
N 806070120Nm
75 90 115 165
SRU1 lbf18131627lbft556685122
N 125 100 110 195 Nm 90 105 130 190
SRU2 lbf28222544lbft667796140
N 165 135 150 260 Nm 100 115 140 205
SRU3/4 lbf37303458lbft74 85 103 151
N 300 250 250 460 Nm 125 145 175 260
SRU5/6 lbf 67 56 56 103 lbft 92 107 129 192
Direction of flow:
The direction of flow is dictated by the direction of rotation of the drive shaft. Reversing the direction of rotation will reverse the
flow direction.
Suction Discharge
Discharge Suction
Discharge Suction
Suction Discharge
10

4 Installation
To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the
following should be taken into consideration.
Pump Lubrication:
The pump will not be supplied pre-filled with oil therefore this table must be used to select recommended oil.
Oil changing: Oil level must be checked with the pump static.
First change: After 150 hours of operation, thereafter every 3000 hours of operation.
Oil filling: Fill with oil through the filler plug to the level indicated in the sight glass.
NOTE!
On horizontally ported pumps the sight glass must be fitted to the upper hole on the side of the gearcase. Refer to 6 Technical
datafor oil approximate quantities required
Recommended Oils
Pump Operating Temperature Food grade oils (USDA H1)
-20°C to +130°C +130°C to 200°C -20°C to +130°C
(-4°F to +266°F ) (+266°F to 392°F) (-4°F to +266°F)
BP Energol GR - XP150 BP Enersyn SG-XP150 Bel-Ray No-Tox HD Food Grade Oil 150 #62686
Castrol Alpha SP150 Castrol Alphasyn PG150 Mobil SHC Cibus 150
Mobil Mobilgear 600 XP150 Mobil Glygoyle 30 Castrol Optileb GT150
Shell Omala S2 G150 Shell Omala S4 WE150
Texaco Meropa 150 Texaco Synlube CLP220
Esso Spartan EP150 Mobil Glygoyle 22
For ATEX applications refer to ATEX addendum manual.
Baseplate Foundations
Pumps when supplied with a drive unit are normally mounted on a baseplate. Our standard baseplates have pre-drilled fixing
holes to accept base retaining bolts. To provide a permanent rigid support for securing the pump unit, a foundation is required
which will also absorb vibration, strain or shock on the pumping unit. Methods of anchoring the baseplate to the foundation
are varied, they can be studs embedded in the concrete either at the pouring stage as shown below, or by use of epoxy
type grouts. Alternatively mechanical fixings can be used.
Waste put around bolt before pouring concrete Foundation surface left through to anchor ground
One D Minimum Sleeve
3D
One-half D Minimum Lug welded to bolt head
D
4D
10D
TD 243-101
The drawing above shows two typical methods for foundation bolt retaining. The sleeve allows for “slight” lateral movement of
the bolts after the foundation is poured. Rag or waste paper can be used to prevent the concrete from entering the sleeve
while the foundation is poured. A minimum of 14 days us normally required to allow the curing of the concrete prior to
pump unit installation.
11

4 Installation
To ensure optimum operation it is important that any pump unit is installed correctly. When designing a pumping system the
following should be taken into consideration.
Coupling alignment:
Before the pump unit is installed is it important to ensure that the mounting surface is flat to avoid distortion of the baseplate,
which may cause pump/motor shaft misalignment and pump/motor unit damage. Once the baseplate has been secured, the
pump shaft to motor shaft coupling alignment should be checked and adjusted as necessary. This is achieved by checking
the maximum angular and parallel misalignment for the couplings as stated below. Shaft alignment that is outside the stated
tolerances can be corrected by applying shims under the motor or pump foot, or, by moving the pump or drive sideways on
the baseplate. All bolts that have been loosened should be re-tightened to the stated torque figure.
The following dimensions and tolerances apply to standard supply couplings only.
Parallel misalignment
Measure 4 positions at 90° around coupling
Coupling size Dimension A Maximum
70 0.3 mm
90 0.3 mm
110 0.3 mm
130 0.4 mm
150 0.4 mm
180 0.4 mm
230 0.5 mm
280 0.5 mm
TD 246-090
A
Angular misalignment
Measure 4 positions at 90° around coupling
Coupling size Dimension B Maximum
70 1°
90 1°
110 1°
130 1°
150 1°
180 1°
230 1°
280 1°
TD 246-089
Bo
Assembled length
Coupling size Dimension L ± 1.0mm
70 25
90 30.5
110 45
130 53
150 60
180 73
230 85.5
280 105.5
TD 246-088
L
Recommended bolt torques.
Thread Diameter M6 M8 M10 M12 M16 M20 M24
Torque (Nm) 615 30 50 120 250 200
12

4 Installation
This page is not applicable for ATEX applications.
For ATEX application see ATEX addendum
4.3 Flushing seal arrangement and pre-start up checks
Step 1
A flushed seal arrangement is fitted in order to cool or clean the seal area.
It is important that:
- The flush is correctly connected (see below).
- A compatible flushing fluid is used and supplied at the correct pressure and flow rate (see Step 5).
- The flush is turned on at the same time/prior to starting the pump, and turned off at the same time/after stopping the pump.
Step 2
Connecting the flush
The following equipment is strongly recommended when using a flushing system:
- Control valve and pressure gauge, to enable the correct flushing pressure to be obtained and monitored.
- Isolation valve and check valve, so that the flush can be turned off, and to stop any unwanted substances flowing in
the wrong direction.
- A method of visibly indicating flushing fluid flow.
Step 3
Flushing arrangements in principle
Flush outlet
Flush outlet Link
pipe
Flush intlet
Flush inlet
Serial piping Parallel piping
Step 4
Flushing fluid
The choice of flushing fluid is dependent upon the fluid being pumped and duty conditions i.e. pressure and temperature. Usually
water is used for cooling or flushing water soluble products. For both single and flushed mechanical seal arrangements the
temperature of flush media should never allowed to exceed the maximum temperature of the pumped media. For advice on
selecting a suitable flushing fluid please contact pump supplier.
Step 5
Flushing pressure and flow rate
Single flushed mechanical seal 0.5 bar (7 psi) maximum. Any further increase in pressure will result in lip seal failure. Double
mechanical seal/flushed packed gland 1.0 bar (14 psi) higher pressure than the discharge of the pump. If the discharge
pressure fluctuates set the pressure to suit maximum condition.
The flushing flow rate must be adequate to ensure that the temperature limitation of the seals is not exceeded. Contact your
pump supplier for further information on the recommended flow.
Minimum flow rate required per shaft seal is 30 l/hr
Step 6
Pre-start up checks
- Check the pipework system has been purged to remove debris.
- Check all obstructions have been removed from pipework and pump.
- Check pump connections and pipework joints are tight.
- Check lubrication levels are correct.
- Check seal flushing is connected if applicable.
- Check all safety guards are in place.
- Check that inlet and outlet valves are open.
13

4 Installation
4.4 Recycling information
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 agreement with local regulations.
•Scrapping
- At end of use, the equipment shall 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 the local Alfa Laval sales company.
14

5 Maintenance
5.1 Cleaning in place (CIP)
The pump can be manually cleaned or cleaned in place (CIP). The following is an example of a typical CIP procedure. However
specific advice for each application should be sought from the pump supplier.
Typical CIP procedure
1. Flush through the system with cold water or bore water (6°C) (43°F).
2. Run hot caustic soda (70-80°C) (158-176°F) at 2.5% dilution through the system for 20-30 minutes.
3. Final flush through with cold water again.
Warnings
Never touch the pump or the pipelines as they will be extremely hot!
Do not subject the pump to rapid temperature changes during CIP procedures, as pump seizure
can result from thermal shock.
A suitable by-pass is recommended.
Always rinse well with clean water after using a cleaning agent.
Always use rubber gloves and protective goggles when handling caustic agent.
Always store/discharge cleaning agents in accordance with current rules/directives.
15

5 Maintenance
5.2 Maintenance schedule
It is advisable to install pressure gauges on both sides of the pump so that any problems within the pump/pipework can
be monitored.
Maintenance schedule
Your weekly schedule should include:
- Checking the oil level in the gearcase with the pump stationary.
- Checking the seals for leakage.
- Checking the oil seals for leakage.
- Check pumping pressures.
In certain operational circumstances the pump will pose a thermal hazard and as such should not be touched during operation.
After shutdown the pump unit should be allowed time to cool.
Oil should be changed every 3000 hours of operation or a period of 2 years, whichever is the soonest.
Recommended Spare Parts Part description Quantity
Lip seal drive end 1
O-ring rotorcase cover 1
Lip seal gland end 2
O-ring rotor sealing shaft end 2
O-ring rotor sealing nut end 2
The table shows recommended spare parts
that should be retained within your maintenance
schedule.
Primary seals 2
Rotor nut O-ring Seal Replacement Interval
It is recommended that the rotor nut O-ring seal is replaced every 12 months to maintain a bacteria tight seal.
Rotor Nut Seal Inspection
Periodically inspect the rotor nut O-ring seal for any discoloration, nicks, or cracks. If any of the defects above are noticed,
the O-ring seal must be replaced. Inspection and replacement refer to the seal replacement procedure below.
Seal Replacement Procedure
1. Remove rotor case cover (see 5.3 Dismantling, step Step 1).
2. Undo rotor nuts and ensure components are dry before servicing.
3. With a penlight, inspect rotor nut blind tapped hole for contamination. If soiled, refer to cleaning procedure below.
4. Remove and discard rotor nut O-ring seal.
5. Fit new rotor nut O-ring seal.
6. Fit rotor nut and use a torque wrench to tighten to correct torque value (see table 6.1.3 on page 37).
7. Fit the rotor case cover.
Cleaning Procedure for Soiled Rotor Nut Tapped Hole
1. Remove rotor nut from the shaft.
2. Submerge and soak nut for 5 minutes in COP tank with 2% caustic wash.
3. Scrub the hole with internal thread vigorously by plunging a clean sanitary bristle pipe brush in and out of the hole
for two minutes while submerged.
4. Soak nut in acid sanitizer for 5 minutes, and then scrub the hole again with the pipe brush for two minutes.
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 rotor nut.
16

5 Maintenance
5.3 Dismantling
Step 1
Before dismantling the pump refer to safety precautions. See
exploded view drawings (chapter 7 Parts list).
Removing rotorcase cover
1. Remove rotorcase cover nuts (13) and cover (12).
Step 2
Removing rotors
1. Insert a plastic/wooden block between the two rotors (17) to
stop them turning.
2. Remove rotor retention nuts (22) and rotors. Pump series 6
rotors are retained by torque locking assemblies, TLA’s (19)
andcanberemovedby:
- Remove the rotor cap to reveal the TLA.
- The screws now visible are unscrewed and the TLA is
removed.
Plastic or wooden block
Step 3
1. For packed gland seals loosen the gland followers to relieve the
packing pressure on the shaft.
For flushed mechanical seal arrangements, remove the seal
housing retaining nuts and ease the seal housings from the
rotorcase.
2. Remove rotorcase retaining nuts (4) and washers (4A).
3. Tap both sides of the rotorcase (9) with a soft mallet.
4. Take care not to damage mechanical seals. The rotorcase
must not be allowed to drop onto the shafts (24 and 25) during
the removal process.
5. Shims (8) should not be removed unless rotor clearances
require resetting.
Step 4
Draining pump lubrication
1. Place a tray under the gearcase to collect the waste lubricating
oil.
2. Remove the lower drain plug (45) at the side of the gearcase (1).
17

5 Maintenance
Step 5
Removing seal retainers
1. Remove screws (15).
2. Then remove seal retainers (14) - as a liquid sealant has been
used a lever may be required to remove retainers.
3. The lip seals (16) can be removed using a screwdriver/ lever
once the seal retainers are removed. It is essential to renew the
lip seals and it is recommended that new gaskets or sealant
be used prior to reassembly.
Step 6
Removing Gearcase Cover
1. Remove screws (6).
2. Remove gearcase cover (5) after breaking the gasket seal then
press out the lip seal (7). It is essential to renew the lip seal
prior to reassembly.
Step 7
Removing timing gears
1. Release clamp plate screws (40) and remove clamp plate (39)
on pump series 1,2 and 3. For pump series 4,5 and 6 remove
the torque locking assembly screws in several stages.
2. Remove gears (36) using the tapped extraction holes provided,
or remove shaft assembly as shown in step 8 below.
Step 8
Shaft assembly removal
1. Using a soft mallet gently tap the rear end of each shaft (24 and
25), to remove through the front of the gearcase (1).
2. Support each shaft during removal from the gearcase.
3. Remove the shaft abutment spacer (27).
- For vertically ported pumps this is placed in the right hand
bearing bore when viewed on the front face of the gear case.
- For horizontally ported pumps the shaft abutment spacer is
placed in the top bearing bore.
18

5 Maintenance
Step 9
Bearing removal
1. Hold the shafts (24 and 25) in a vice using soft jaws to protect
the areas where the seals will be located.
2. Remove the bearing nuts (30) with a ‘sharp tap’ on a ‘C’
spanner. The nuts may be tight all the way off as they are fitted
with thread locking adhesive.
3. Mount the shaft vertically in a press with a tool positively
located against the bearing inner as shown and apply pressure
to the top of the shaft so that the shaft moves through the
bearings (26 and 31).
4. Remove each bearing set (inner and outer). Good engineering
practice suggests that if bearings are removed from the shafts
for any reason they should be renewed.
Clean and examine all components for wear or damage.
Renew where necessary.
19

5 Maintenance
5.4 Assembly
5.4.1 Fitting bearings to shafts
Take care not to damage shaft surfaces, in particular where the seals will be located. Ensure all fastenings are tightened to
torque settings as shown in 6 Technical data.
On series 1, 2 and 3 pumps, bearings do not require heating. For series 4, 5 and 6 pumps, heat the bearing inner cones to
110°C (230°F).
Do not use any form of live flame when heating, as this will damage bearings.
Step 1
Position shaft (24 and 25) vertically in a vice using soft jaws and apply anti-seize compound to the bearing diameters.
Step 2
Place the inner cone on the shaft ensuring a positive fit against
the shaft shoulder.
Step 3
Locate outer cup, bearing spacer (32) and rear bearing cup.
Step 4
Allow bearings to cool (series 4, 5 and 6 pumps only). Failure to do so will result in incorrectly set bearings.
1. Apply Permabond Grade 145 or equivalent locking compound to the bearing nut thread.
2. Tighten the bearing nut (30), whilst at the same time rotating the bearings (26 and 31) and spacer (32). The bearings are
correctly adjusted when the spacer can only be moved with a light tap of a mallet.
3. Repeat the above for double bearing assemblies.
4. Apply oil to the bearings.
20