Alfalaval SX Series User manual

TD 242-113_1
IMPORTANT!
When ordering spare parts please quote Pump Serial No.
Read all of this pump manual and any instructions supplied for ancillary equipment before the unit is installed,
operated or maintained.
ESE02203-EN5 2020-02
Original manual
Instruction Manual
ATEX Addendum to SX Instruction Manual - Rotary Lobe Pumps - SX 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
1.1. ATEX Directive 2014/34/EU ...................................................................... 5
1.2. ATEX marking ..................................................................................... 5
2. Safety .................................................................................................... 6
2.1. Special conditions for safe use .................................................................. 6
2.2. General information ............................................................................... 6
3. Installation .............................................................................................. 7
3.1. Installation ......................................................................................... 7
4. Operation ............................................................................................... 8
4.1. Operation .......................................................................................... 8
4.2. Important checks to maintain Safe Operation ................................................. 8
5. Maintenance ........................................................................................... 10
5.1. Maintanance ....................................................................................... 10
5.2. Ordering Spare Parts ............................................................................. 10
5.3. Heating/Cooling devices ......................................................................... 11
6. Technical information ................................................................................. 12
6.1. Technical data ..................................................................................... 12
6.2. Seal Operation Data Sheet ...................................................................... 14
3

1 EC Declaration of Conformity
This declaration of conformity is issue under sole responsibility of the manufacturer:
Alfa Laval Eastbourne Ltd
Company Name
Brich Road, Eastbourne, East Sussex, BN23 6PQ United Kingdom
Address
[phone]
Phone No.
Equipment covered by this declaration of conformity:
Pump
Designation
SX1, SX2, SX3, SX4, SX5, SX6, SX7
Type
From serial number EXXXXXX to E500000
Is in conformity with the requirements of the following directives:
2006/42/EC Machinery Directive
2014/34/EU Equipment Explosive Atmospheres (ATEX)
This declaration of conformity covers pumps with the following ATEX markings:
II 2G Ex h IIB T4 .. T2 Gb II 3G Ex h IIB T4 .. T2 Gc
II 2G Ex h IIC T4 .. T2 Gb II 3G Ex h IIC T4 .. T2 Gc
For ATEX directive 2014/34/EU the following harmonized standards EN 80079-36:2016 and EN 80079-37:2016 for non-electrical
equipment have been applied.
ATEX directive 2014/34/EU conformity for the motor and coupling is covered by the relevant EU Type examination
certificates and declarations supplied by the manufacturers.
The Pump Technical File is stored with: Teknologisk Institut, Kongsvang Alle 29, 8000 Aarhus C, Denmark
Notified Body no.: 0396
Archive no.: 2019-1-0331A
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 2020-02-11
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated 2018-06-01)
4

1 EC 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, vapors and dusts.
Rotary Lobe 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/or 3.
Technical File Ref: 2019-1-0331A
Equipment Group and Category: Group II Category 2G Zone 1
Group II Category 3G Zone 2
Standards used: EN 80079-36:2016; EN 80079-37:2016
1.2 ATEX marking
ATEX marking
New drawing
In addition to the standard pump nameplate, ATEX Certified
units have an additional ATEX name plate affixed to the pump
gearbox housing stating the unit ATEX certification standard.
Name plate example:
[Nameplate Drawing Placed Here - Center Justified]
5

2Safety
Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of
special signs, see description in Standard Instruction Manual section 2.1 Special Conditions for Safe Use and 2.22.2 General
Information.
Always read the manual before using the pump!
2.1 Special conditions for safe use
!
-Never operate pump outside max duty conditions specified in “Seal Operation Data” section 6.2. If the duty conditions
change please refer to pump manufacturer.
-Ensure checks and running conditions for pump or pump unit during operation to be according to “Operation” section 4 .
2.2 General information
!
-Always make sure that the Serial Number Stamped on the pump nameplate matches the number shown on the Declaration
and on the Seal Operating Data in Section 6.2 .
-Always check that the components and equipment supplied is suitable for the area intended and corresponds with the
order acknowledgement.
-Always read this ATEX addendum thoroughly before using the pump and read the safety instructions in the Standard
Instruction Manual prior to handling, installing, operating or maintaining the pump.
-Always order genuine spare parts using the serial number of the pump, stated on the pump nameplate, for identification.
-Always ensure that intentionally or potentially mixing of fluids do not create hazardous reactions/situations (eg. process
media and flush media)
Education:
Operators must have necessary knowledge about the pump supplied including the mechanical seals before doing any
installation or maintenance work relating to the pump or pump unit. Necessary knowledge includes the understanding of the:
- function of the pump/pump unit including the mechanical seal.
- maintenance/service procedures of the pump/pump unit including the mechanical seals.
- safety instructions.
- operational limits for the pump/pump unit including the mechanical seals
Installation
-Alway
s read section 3 “Installation”
Operation
- Always read section 4 “Operation”
Maintenance
-Al
ways read section 5 “Maintenance”
6

3 Installation
3.1 Installation
!
Pumps and motorized pump units
-Always follow the Installation instructions in the Standard Instruction Manual in conjunction with this addendum.
-Always ensure that instructions for all ATEX compliant equipment and components are followed (motors, couplings,
reduction gears etc.)
-Always make sure that pump gearbox, base plate and motor are electrically earthed
-Always read section 4 “Operation” before pump start up.
-Never install the pump or pump unit at an angle of more than 5° from the horizontal plane
-Never cover up pump gearbox, motor or reduction gearbox in any way that will reduce the cooling effects intended
-Ensure correct alignment of pump and drive unit
-Ensure that all control and monitoring equipment complies with the requirements in appropriate ATEX standards e.g.
EN 13463-6
Flush system
-Always measure flush media parameters at the flush outlet on the pump rotorcase eg. temperature, flow and/or pressure
(see Technical data, section 6.1, for more information)
TD 242-122
7

4Operation
4.1 Operation
!
Pumps and pump units
-Always read the operations instructions in the Standard Instruction Manual
-Always read “Technical information” for shaft seals in section 6.1
-Always vent and purge the pump head and seal cavities of air/gas prior to start-up to avoid dry-run
-Always make a visual inspection of the pump unit at startup to ensure there are no malfunctions e.g. leaks, abnormal noises,
vibration or heat. If found the equipment must be stopped immediately and the cause rectified.
-Always remove the rotorcase cover to drain the pump head. The rotor case is not self-draining.
-Never use the single seal options in applications where dry-running is predictable and/or where leakage from the shaft
seal can cause a hazardous situation (double mechanical seal recommended).
-Never run pump with suction side and/or pressure side blocked. Process systems should be installed/controlled in a
way so this cannot occur
-Never operate other equipment/components in pump unit outside limits specified in manufactures instructions manuals eg.
motor, reduction gear, coupling etc.
-Never use a heating/cooling media in jackets, which can cause a hazardous situation in case of leakage
-Ensure that the temperature of the heating jacket, if fitted, does not exceed , vibration or heat. If found the equipment must
be stopped immediately and the cause rectified.
-Always take care when choosing flush media such that a hazardous situation does not arise with seal leakage.
4.2 Important checks to maintain Safe Operation
In order to function correctly, mechanical seals are dependent upon lubrication and cooling of the sealing surfaces, using either
pumped or barrier/buffer media. When either pumped or barrier/buffer media is not present, the seal will dry-run. Dry-running
seal faces must be avoided at all times, as this will cause excessive and uncontrolled heat generation of the seal faces. This in
turn could lead to exceeding the specified temperature class and thereby increasing ignition (explosion) risk. If dry-running
cannot be avoided, then a flushed mechanical seal must be used. In order to ensure that the mechanical seal faces are
lubricated and properly cooled, end users are required to monitor the pump/seal arrangement in such a way that this is achieved.
For pumps fitted with double mechanical seals (high pressure flush), the end user is required to ensure:
-Flushm
edia is present
-Flush
media is at a pressure 1.0 bar min. above the pump discharge pressure.
- Seal faces are receiving the required volume of flush media, to cool them and so dissipate any heat build up.
In practice this means the end user must monitor:
- Flush media pressure
- Flush media flow rate
- Temperature - either at outboard seal face or of flush media.
For pumps fitted with double mechanical seals (low pressure flush), the end user is required to ensure:
- Flush media is present
- Seal faces are receiving the required volume of flush media, to cool them and so dissipate any heat build up.
In practice this means the end user must monitor:
-F
lush media pressure or flow rate
-T
emperature - either at outboard seal face or of flush media.
For pumps fitted with single mechanical seals, the end user is required to ensure:
- Seal face temperature does not exceed temperature class limit.
In practice this means the end user must either monitor:
- Presence of pumped media either by flow rate or pressure indicator.
- Temperature - either pumped media or seal face.
8

4Operation
Daily checks (category 2 only)
Shaft seal, all types
- Ensure there is no unacceptable leakage
Pump units
- Ensure the oil levels to be correct with no signs of oil contamination.
- Ensure there are no signs of overheating.
- Ensure there are no abnormal running conditions such as loose components, abnormal noise, vibration, heat or oil leakage.
If found the equipment must be stopped immediately and the cause rectified.
- Ensure all sealing elements are effective to prevent ingress of solid foreign objects and liquids.
- Ensure the pump duty conditions never exceed the limits specified in ‘Seal Operation Data’ section 6.2.
- Ensure that any dust deposits are removed.
Control/monitoring equipment
- Ensure, at least daily, correct function of control and monitoring equipment so as to ensure surface temperatures to stay
within the specified temperature class (eg. process media temperature/pressure sensors)
- Ensure, at least daily, correct function of signals, alarms and associated Ignition Prevention Systems so as to ensure surface
temperatures stay within the specified temperature class
Weekly checks (Category 3 only)
The above checkpoints listed under “daily checks..” should be carried out on a weekly basis
Other checks
Pumps and pump units, category 2 and 3
- Ensure that Pump duty conditions and running speed never exceed limits specified in “Seal Operation Data” section 6.2.
Pump units, category 2 and 3
- Ensure surface temperatures on motor and reduction gearbox stay within the limits of the appropriate temperature Class e.g.
T4. See manufacturers instructions.
NOTE:
Any maintenance work must be carried out when an explosive atmosphere is not present. Additionally, prior to any maintenance
work the equipment must be electrically and mechanically isolated.
9

5 Maintenance
5.1 Maintanance
Maintenance
-Always follow the Maintenance instructions in the Standard Instruction Manual
-Always read “Technical information” section 6.1 and the “Seal Operation Data” section 6.2
-Always ensure that instructions of all ATEX compliant equipment and components are followed (motors, couplings,
reduction gears etc.)
-Always read section 4 “Operation” before starting up the pump unit after maintenance
-Always replace pump gearbox lip seals if they are disturbed i.e. cover removed.
Pump Gearbox
The oil in the gearbox acts as a coolant/lubricant for the bearings, lip seals and timing gears. Also the oil acts as ignition
prevention and thus it is essential to ensure the oil level to be correct as specified in the standard instruction manual.
Recommended oil as follows:
(-20 to +130°C) (+130to+20
0°C) Food Grade (-20 to +130°C)
Castrol Alphasyn PG150 Castrol Alphasyn PG 220 Mobil Glygoyle 150
Mobil Glygoyle 22 Mobil Glygoyle 30 Tot al Ne v a stane XSH 150
Shell Omala S4 WE 150 Shell Omala S4 WE 220 Fusch Cassida Fluid GL 150
Chevron Meropa Synlube WS 150 Chevron Meropa Synlube WS 220
Pump Gearbox bearings changing intervals
If the bearings are worn excessively it can cause increased friction and thus increased surface temperature on the gearbox.
Gearbox bearings should be renewed before the running hours stated in the table below have been exceeded. Alternatively it
should be ensured by other means that the bearings are working satisfactorily eg. bearing frequency analysis. The bearings
should be checked/monitored continuously or at least every 1000 running hours when the running hours in the table below
are exceeded.
Bearing changing intervals
(pump running hours x 1000)
Process media differential pressure
Pump Model 0to7b
ar 7to10bar 10 to 15bar
SX1/005 30 23 13*
SX1/007 19 --
SX2/013 30 30 15
SX2/018 30 --
SX3/027 30 30 18
SX3/035 30 --
SX4/046 30 30 30
SX4/063 30 30 -
SX5/082 30 30 22
SX5/115 30 30 -
SX6/140 30 30 17
SX6/190 30 28 -
SX7/250 30 30 9
SX7/380 30 10 -
* SX1/005 only goes from 0 to 12 bar
5.2 Ordering Spare Parts
When ordering spare parts please quote Pump Serial No.
10

5 Maintenance
5.3 Heating/Cooling devices
SX pumps have the option of being fitted with jackets to the rotorcase cover These are primarily used for heating the pumphead
so as to maintain the pumped media temperature. They may also be used for cooling purposes.
Jacket New picture
Corrections
for steam,
hot/cold fluid
The maximum allowable pressure and temperature of heating/cooling fluid is 3.5 bar (50 psi) and 150°C (302°F) respectively,
except in T4 applications in which the maximum allowable temperature is 115°C.
11

6 Technical information
6.1 Technical data
Shaft seals
Mechanical seals are dependant upon lubrication and cooling of the sealing surfaces. Therefore dry-running of the seal faces must
be avoided since this can cause excessive generation of heat and thus possibility of exceeding the specified temperature class.
During normal operation a mechanical seal will generate a small but controlled leakage. This leakage will increase upon failure.
Due to the working principles of mechanical seals a flush system must be monitored if dry-running of the process media cannot
be avoided or if leakage of the product media can cause a hazardous situation (eg. flammable products).
All control and monitoring equipment used to ensure that the seal operating conditions stay within specified limits should
comply with appropriate ATEX standards e.g. EN 13463-6.
There are two standard mechanical seal options conforming with ATEX
1. ATEX compliant double flush mechanical seal (Vertically ported pumps only)
These seals provide the user with the highest level of protection against the mechanical seal faces running hot.
Proper function of the flush system is essential. If the flush stops, the outboard seal will run dry and thus the seal face
temperature will increase and possibly be a potential explosion risk.
Refer to standard Instruction Manual for seal removal and fitting.
There are two basic types of flush:
Double Flushed Mechanical Seal (high pressure flush)
On this seal arrangement the flush is used as a ‘Barrier’ fluid. The pressure of the barrier fluid should be 1.0 bar min. above the
pump discharge pressure. The inboard seal interface film will therefore be flush media. The barrier fluid will act as a coolant and
lubricant for both inboard and outboard seals. Leakage of pumped media into the barrier fluid will not occur.
Double Flushed Mechanical Seal (low pressure flush)
On this seal arrangement the flush is used as a ‘Buffer’ fluid. The pressure of the buffer fluid should be as low as possible, but
below the pump discharge pressure. The inboard seal interface film will therefore be pumped media. The buffer fluid will act as
a coolant for the inboard seal and carries any leakage of pumped media away to ensure good seal function. The buffer fluid
also acts as a coolant and lubricant for the outboard seal.
Ensuring seal face temperature
It must be ensured that the temperature of the seal face does not exceed the temperature class limit. This can be achieved by:
a) ensuring that the temperature of the buffer/barrier fluid does not exceed the value listed on “Seal Operation Data” and that the
total flow is at least 30 litres/hour. The temperature and flow must be measured after the flush outlet on the pump rotorcase.
If a recommended flow higher than 30 litres/hour is stated on the “Seal Operation Data” this should be followed.
b) ensuring that the temperature of the buffer/barrier fluid does not exceed the value listed on “Seal Operation Data” and that the
total flow is high enough to ensure the flush media to reach the temperature sensor within 10 seconds after leaving the flush
outlet on the pump rotorcase. The distance between the flush outlet on the pump rotorcase and the temperature sensor should
not exceed 200mm. This applies when the flow of the flush media is lower than 30 litres/hour.
NOTE:
For good seal function and life a general minimum flow of 30 litres/hour is recommended.
However, the flow can be lower from an explosion risk aspect under the circumstances described in b). Preferably the
temperature sensor should be mounted as close to the flush outlet on the pump rotorcase as possible. By lowering the flow
below 30 litres/hour the seal life and function might be compromised in some applications.
Thermosyphon flush system is not recommended.
For further information on the installation and operation of the Thermocouple please see section 5.5 Thermocouple
12

6 Technical information
2. ATEX compliant single mechanical seal. There is NO monitoring device or protection built into this seal option. It relies on
the process fluid to cool and lubricate the seal faces in order to stay within the stated temperature class. The process must be
controlled/monitored in a way, which ensures the seal face not to exceed the temperature limit. This can be done by ensuring
that there is a reasonable flow of the process fluid and that the process temperature does not exceed the values listed in
“Seal Operation Data” section 6.2.
Single mechanical seals are not suitable for applications/duties where leakage of process fluid can cause a hazardous situation.
Single mechanical seals should not be allowed to run dry.
Refer to standard Instruction Manual for removal and fitting.
For further information on the installation and operation of the Thermocouple please see section 5.5 Thermocouple
13

6 Technical information
6.2 Seal Operation Data Sheet
6.2 Seal Operation Data Sheet attached here.
14

15

How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.