GEA Hilge CONTRA I ADAPTA User manual

Hygienic Pumps
GEA Hilge CONTRA I/II ADAPTA
Operating instruction (Translation from the original language)
BA.10A.ADY.001.GB_1

COPYRIGHT
All rights reserved.
Nothing contained in this documentation may be reproduced or distributed in any
form (print, photocopy, microfilm or another method) without the prior written
permission of
GEA Hilge
Office of GEA Tuchenhagen GmbH
hereinafter referred to as Manufacturer in any form (print, photocopy, microfilm
or other process) reproduced or distributed. This restriction also applies to the
drawings and diagrams included in the documentation.
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LEGAL NOTICE
These instructions are part of the technical documentation for the scope of
delivery. They contain important information to ensure safe and proper
transportation, mounting, commissioning, economic operation, maintenance, and
repair of the pump. Following these instructions will help you avoid risks, reduce
repair costs and downtime and increase the pump's reliability and service life.
These instructions are aimed at users of the pump and are intended in particular
for the operator and its operating and maintenance personnel.
It is mandatory for the operator and its operating and maintenance personnel to
read these instructions prior to transport, installation, commissioning, use,
maintenance, repair, disassembly and disposal of the pump. The obligation to
read these instructions applies also to persons responsible for carrying out
activities in the phases of the life of the pump.
The operator is required to complement these instructions with information based
on existing national regulations for occupational safety, health protection, and
environmental protection.
In addition to these instructions and the mandatory regulations for accident
prevention applicable in the country and place of use, the recognised technical
rules for safe and proper work must be observed.
These instructions are part of the pump. The entire documentation consists of
these instructions and any additional instructions provided. It must always be kept
within reach at the pump’s location of use. When moving the pump to a different
site and upon selling the pump, the entire documentation must be passed on as
well.
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These instructions were written to the best of our conscience. However, the
manufacturer is not liable for any errors that may be contained in this document
or for any resulting consequences.
The manufacturer reserves the right to make technical changes by further
development of the pump described in these instructions.
Illustrations and drawings in these instructions are simplified representations.
Due to enhancements and changes, it is possible that the illustrations do not
exactly match the pump used by you. The technical data and dimensions are not
binding. Claims cannot be derived from them.
The manufacturer assumes no liability for damages
•arising within the warranty period due to
–unintended operation and usage conditions,
–insufficient maintenance,
–improper operation,
–incorrect installation,
–incorrect or improper connection of electrical components.
•resulting or arising from unauthorised modifications or failure to follow the
instructions,
•caused by use of accessories / spare parts that have not been supplied or
recommended by the manufacturer.
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LAYOUT INFORMATION
Bullet points and numbered list characters
Bullet points are used to separate logical contents within a section:
•Bullet point 1
Types of bullet point 1.
•Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a
descriptive text:
Descriptive text with consecutive numbering:
–Numbered list point 1
–Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps
result in a handling sequence that should be run in the specified order. The
handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
–step 1,
–step 2,
–step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
®Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
–Individual work steps
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TABLE OF CONTENTS
1 General 9
1.1 Information about this document 9
1.2 Manufacturer address 9
1.3 Customer Service 9
1.4 EU Declaration of Conformity for Machines 10
2 Safety 11
2.1 Intended use 11
2.1.1 Pumped fluids 11
2.1.2 Minimum flow rate 11
Minimum flow rates in explosive atmospheres 11
2.1.3 Connections and piping 11
2.1.4 Switching frequency 11
2.1.5 Types 11
2.2 Safety precautions in these operating instructions 11
2.3 Explanation of the safety symbols used 13
2.4 Safety instructions for the company/operator 13
2.4.1 Dangers of non-compliance with safety information 14
2.4.2 Safety-conscious work behaviour 14
2.5 Unauthorised modification and ordering of spare parts 14
2.6 Staff qualifications and training 15
2.7 Safety equipment 15
2.8 Possible residual hazards 15
3 Description 17
3.1 Pump overview 17
3.2 Description 18
3.2.1 Standard version applications 18
3.2.2 Hygienic design applications 18
3.3 Pump name 18
3.4 Type plate 18
4 Transport and Storage 20
4.1 Special personnel qualification for transport and storage 20
4.2 Safety precautions for transport and storage 20
4.3 Safety instructions for transporting the pump 20
4.4 Attachment points for lifting loads 20
4.5 Storage of the pump 20
4.6 Dimensions / weights 21
4.7 Unpacking the pump 22
4.8 Disposal of packaging material 22
5 Technical data 23
5.1 Serial number 23
5.2 Performance data 23
5.3 Noise emissions 23
5.4 Maximum operating temperatures 24
5.5 Maximum operating pressure 24
5.6 Resistance of Sealing Materials 25
6 Assembly and installation 26
6.1 Safety precautions for setup, installation, and connection 26
6.1.1 Mechanical seals in tandem arrangement 28
6.1.2 Mechanical seals in back-to-back arrangement 28
6.1.3 Vertically installed pumps 28
6.2 Special personnel qualification 28
6.3 Setup, installation, and connection 28
6.3.1 Checking smooth running of the impeller 29
6.3.2 Setting up and aligning the pump unit 29
6.3.3 Installation in the piping system 30
Space requirements 30
Noise and vibration damping 31
6.3.4 Using the mechanical seal 33
6.3.5 Flush connections for double mechanical seals (optional) 34
Flushing fluid (optional) 34
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Double mechanical seals (optional) 34
6.3.6 Electrical connection 37
Star connection 37
Delta connection 37
Frequency converter operation 37
Checking the direction of rotation after connecting 38
Earthing 39
7 Commissioning 40
7.1 Special personnel qualification 40
7.2 Safety instructions for commissioning 40
7.3 Commissioning / initial startup 40
7.3.1 Checking conditions of use 40
7.3.2 Vent pump 41
7.3.3 Commissioning of the pump 41
7.3.4 Functional testing of the mechanical seal 42
8 Cleaning 43
8.1 Special personnel qualification 43
8.2 Safety instructions 43
8.3 CIP 44
8.4 SIP 45
8.5 Manual exterior cleaning 45
9 Maintenance / servicing 46
9.1 Safety instructions for maintenance and repair 46
9.2 Special personnel qualification 46
9.3 Pump maintenance 46
9.3.1 Inspections 46
Replacement of O-rings 46
9.3.2 Maintenance intervals 47
9.4 Maintenance of the ADAPTA bearing 47
9.4.1 Bearing housing design sizes 1 and 2 47
9.4.2 Bearing housing design size 3 48
9.4.3 Bearing replacement 48
9.4.4 Premature bearing replacement 48
9.4.5 Grease filling 49
Roller bearing greases 49
9.5 Maintenance of the motor 50
10 Malfunctions / repairs 51
10.1 Special personnel qualification 51
10.2 Safety instructions 51
10.3 Malfunctions and remedies 52
10.4 Repair 53
10.4.1 Repair order 53
10.4.2 GEA Hilge assembly tool kit 55
Contents and use 55
10.4.3 Parts overview 56
10.4.4 Parts overview of ADAPTA bearing housing sizes 1 and 2 57
10.4.5 Parts overview ADAPTA bearing housing size 3 58
10.4.6 Parts overview of coupling and motor 59
10.4.7 Disassemble the pump 59
10.4.8 Installation instructions 60
Cleaning the components before assembly 60
10.4.9 Installing ADAPTA bearing housing size 1 and 2 61
10.4.10 Installing ADAPTA bearing housing BG 3 66
10.4.11 Fasten discharge casing - simple mechanical seal 72
10.4.12 Installing single conical spring mechanical seal 73
10.4.13 Installing the single mechanical seal - spring encapsulated (hygiene) 75
10.4.14 Installing double mechanical seal 77
10.4.15 Installing tandem double mechanical seal 82
10.4.16 Installing double mechanical seal in back-to-back position 84
10.4.17 Installing impeller and housing 86
11 Decommissioning 93
11.1 Special personnel qualification 93
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11.2 Safety instructions 93
11.3 Temporary decommissioning 93
11.4 Disposal 93
12 Appendix 94
12.1 Clearance certificate 94
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1 General
1.1 Information about this document
Target group
These operating instructions are intended for:
–the operator/user of the pump,
–the maintenance and service personnel.
The instructions assume a general common technical understanding, which is
necessary for the commissioning, maintenance and servicing of pump units.
Sections that are aimed only at special authorised personnel are indicated by a
preceding note
Text highlights
The following symbols and text formatting facilitate the reading of this document:
–Bullets and lists points
–Instructions
Instructions that must be executed in a certain order are numbered according to
the sequence.
For the marking of safety instructions, please refer to Section 2.3, Page 13.
Technical changes
Versions, technical data and spare part numbers are subject to technical change.
We reserve the right to implement changes due to technical progress.
1.2 Manufacturer address
GEA Hilge
Niederlassung der GEA Tuchenhagen GmbH
Hilgestraße 37-47
55294 Bodenheim
Germany
Phone [phone]
Fax [phone]
[email protected]
gea.com
1.3 Customer Service
Phone [phone] (Sales support)
Phone [phone] (Service)
[email protected]
General
Information about this document
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1.4 EU Declaration of Conformity for Machines
in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer: GEA HILGE
Office of GEA Tuchenhagen GmbH
Hilgestrasse 37-47
D 55294 Bodenheim Germany
We declare under our sole responsibility that the machine
Designation: Centrifugal pump
Model: GEA Hilge CONTRA I/II
Type: ADAPTA, ADAPTA-SUPER
conforms with all the relevant provisions of this directive and the following directives:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized
standards, in particular:
EN 809:1998/A1+AC(D)
EN ISO 12100:2010
Remarks: We also declare that the relevant technical documentation for
this machine has been prepared in accordance with Annex VII,
Part A, and agree to submit the documentation on justified
request of national authorities on a data carrier.
Person authorised for compilation and
handover of technical documentation:
GEA HILGE
Office of GEA Tuchenhagen GmbH
Hilgestrasse 37-47
55294 Bodenheim Germany
Bodenheim, 26/03/2018
Michael Wulle
Managing Director p.p. Dr. Boris Kneip Head, Development Dept. GEA Hilge
General
EU Declaration of Conformity for Machines
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2 Safety
2.1 Intended use
Warning!
Non-intended use!
► Pump only media that are specified in the order. The pump has been
specially designed for them.
► Operate the pump only on the electrical grid that was specified in the
purchase order.
2.1.1 Pumped fluids
Use only clean or lightly polluted liquids as pumped fluids as long as they do not
chemically or mechanically attack the pump materials or reduce their strength. If
you want to pump liquids with higher viscosity than that of water, check for
possible overload of the motor.
2.1.2 Minimum flow rate
The pump may not be operated below of a flow rate of Qmin = 10-15 % Qopt.
2.1.2.1 Minimum flow rates in explosive atmospheres
For pumps used in explosive atmospheres according to EU explosion protection
directive 2014/34/EU, the minimum flow rates of the ATEX additional instructions
in Annex B apply.
2.1.3 Connections and piping
The pipe nominal diameters of the system should be equal to or greater than the
pump nominal diameters DNE (suction side) or DNA (pressure side), and the
fittings to the pump should match exactly the type standard of the fixed mating
connection part on the pump. The suction line must be hermetically sealed and
routed such that no air pockets can form. Avoid tight bends and valves directly in
front of the pump. On the suction side, a straight settling section with a minimum
length of 5 times the pipe diameter should be provided. The suction head of the
system must not be larger than the suction head guaranteed by the pump.
2.1.4 Switching frequency
Do not exceed a switching frequency of 15 switching operations per hour.
2.1.5 Types
All information and descriptions in these operating instructions on the use and
handling of the pumps refer exclusively to the standard versions. Special designs
and customised deviations as well as random external influences in the use and
operation are not included in this provision.
2.2 Safety precautions in these operating instructions
Read the safety precautions!
Safety
Intended use
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These operating instructions contain basic precautions that must be observed
during installation, operation and maintenance. They must therefore be read by
the installer and relevant personnel or operator prior to installation and
commissioning. The operating instructions must always be available at machine/
system site.
In addition to the general safety precautions listed in this chapter on safety, be
sure to read also the other, special safety precautions included.
Safety
Safety precautions in these operating instructions
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2.3 Explanation of the safety symbols used
Danger
Stands for an immediate danger which leads to heavy physical injuries or to
the death.
► Description to avert the danger
Warning!
Stands for a possibly dangerous situation which leads to heavy physical
injuries or to the death.
► Description to avert the dangerous situation.
Caution!
Stands for a possibly dangerous situation which could lead to light physical
injuries or to damages to property.
► Description to avert the dangerous situation.
Notice
Stands for an important tip whose attention is important for the designated
use and function of the product.
► Description of the necessary action for proper operation of the product.
2.4 Safety instructions for the company/operator
Follow the safety instructions contained in this operating manual, the relevant
national accident prevention regulations as well as any internal working,
operating, and safety provisions of the operating company.
Warning!
Hot or cold machine parts
Risk of burns.
► Secure hot or cold machine parts against contact!
Warning!
Rotating machine parts
Hazard of entrapment or entanglement.
► Do not remove contact protection for rotating machine parts (e.g.
coupling)!
► Replace defective safety devices promptly!
Safety
Explanation of the safety symbols used
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Warning!
Hazardous materials
Contact with dangerous substances, e.g. by inhalation.
► Discharge the leakage of dangerous goods such that no danger to
persons and the environment arises!
► Comply with legal provisions!
► Switch off the pump in the event of failure of the mechanical seal.
Replace the mechanical seal before next use!
Warning!
Tripping and falling hazard
Danger due to electrical cables.
► Route the electrical supply line such that there is no risk of tripping (only
for pumps on a chassis).
Danger
Live parts
Electric shock by touching live parts
► Use only technically flawless plugs and cables.
2.4.1 Dangers of non-compliance with safety information
Ignoring the safety instructions can result in bodily harm to persons as well as
environmental harm and machine damage.
Failure to follow the safety instructions will result in the loss of any claims for
damages.
Failure to follow the instructions may entail the following hazards, for example:
–Failure of important functions of the machine/system.
–Failure of prescribed methods for repair and maintenance
–Exposure of persons to electrical, mechanical, and chemical hazards.
–Environmental risks caused by leakage of hazardous substances.
2.4.2 Safety-conscious work behaviour
Follow the safety instructions contained in this operating manual, the relevant
national accident prevention regulations as well as any internal working,
operating, and safety provisions of the operating company.
2.5 Unauthorised modification and ordering of spare parts
Modification or alteration of the machine is only permitted with the written
permission of the manufacturer.
Exclusive use of original spare parts and accessories authorised by the
manufacturer ensures safety. The manufacturer will bear no liability for
consequences arising from the use of unauthorised parts.
Safety
Unauthorised modification and ordering of spare parts
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2.6 Staff qualifications and training
The staff for working on and with the pump must have the appropriate
qualifications. Responsibilities, competencies and supervision of staff must be
clearly defined by the operating company. If personnel do not have the necessary
knowledge, they are to be trained and instructed. If necessary, this can be done
by the product manufacturer/vendor on behalf of the operating company. The
operating company must also ensure that the contents of the operating
instructions are fully understood by the staff.
2.7 Safety equipment
Do not remove instructions from the pump.
Signs attached directly on the machine, such as an arrow to indicate the direction
of rotation, must absolutely be observed and kept in fully legible condition.
Damaged or illegible signs must be replaced.
2.8 Possible residual hazards
Hint!
Despite careful design of the machine and the implementation of all
safety-relevant regulations, further risks for persons and machine
during all life phases of the pump cannot be fully ruled out. The
additional safety instructions in the individual chapters of this manual
must therefore be carefully observed!
The residual risks that were ascertained during the risk assessment carried out
for the product according to safety standard EN ISO 14121 - Safety of Machines -
are:
–mechanical hazards due to sharp sheet metal edges and projecting parts
–electrical hazards as a result of inadvertently coming in contact with terminals
and cables
–thermal hazards as a result of inadvertently coming in contact with pump
housings and pipes
–exposure to noise
–hazards caused by vibration due to improper installation
–hazards due to working materials and other materials in case of allergies or
the like.
–neglect of ergonomic principles
–combinations of various hazards
–unexpected starting, unexpected rotation in case of wrong electrical
connections or defects
–shut down, emergency stop when defects are detected
–changes to the rotational speed
–power failure
–Hazard from insufficient / incorrect cleaning - Product contamination,
Safety
Staff qualifications and training
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–failure of the control circuit or control loop
–incorrect assembly
–fracture during operation
–operating media or objects getting thrown out
–loss of stability
–personnel slipping, tripping or falling
Safety
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3 Description
3.1 Pump overview
0156
0153
0801
0107
0330
0180 B
0680
0180 A 0181
Fig.1
0107 - Discharge casing
0153 - Suction port
0156 - Discharge port
0180 A - Foot (combi foot)
0180 B - Foot (cast iron foot)
0181 - Pump stand (vertical stand)
0330 - Bearing housing
0680 - Shroud
0801 - Flanged motor
Description
Pump overview
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3.2 Description
The pump is a end suction, single-stage centrifugal pump in system block design.
All wetted parts are based on the “hygienic design” guidelines. The material
grade 1.4404 or 1.4435 Fe ≤ 1% and the respective execution standard are
carried out according to the order and, if required, certified in writing
3.2.1 Standard version applications
The standard version of the pumps is used in the following areas:
–Breweries (beer, wort, mash, yeast, etc.)
–Dairies (milk, milk mixes, cheese production, etc.)
–Soft drinks (fruit juice, lemonade, mineral water, etc.)
–Wine and sparkling wine production
–Distilleries (mash, distillates, etc.)
–Food production (marinades, pickle, cooking oil, etc.)
–Cleaning systems (CIP)
3.2.2 Hygienic design applications
Due to the consistent hygienic design and the use of pore and porosity-free
materials, the pump is ideally suited for use in the following areas:
–pharmaceutical industry
–medical technology
–in biotechnology process plants
Special applications arise in the area of ultrapure water delivery/WFI, as well as
in equipment for the production of parenterals and infusion solutions according to
FDA.
3.3 Pump name
GEA Hilge pump name
GEA Hilge CONTRA I / 3 ADAPTA 40/40 3 2
Pump name Size / number
of stages Design type Nominal width Output
[kW]
Number of
poles
3.4 Type plate
GEA Hilge
Niederlassung der GEA Tuchenhagen GmbH
Hilgestrasse - D - 55294 Bodenheim
Pump-Type:
Ser.-No.:
Q: H: n:
P:
TAG No.:
YOM: Made in Germany
Fig.2: Type plate GEA Hilge
Description
Description
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Pump type: Pump name P: Motor rating
Serial No.: Serial number n: Speed
Q: Flow rate TAG No.:customer name
H: Delivery head YOM: Year of manufacture
Note: The type plate may differ from the presented layout.
Description
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4 Transport and Storage
4.1 Special personnel qualification for transport and storage
Transports may only be carried out by qualified staff, who must observe the
safety instructions.
4.2 Safety precautions for transport and storage
4.3 Safety instructions for transporting the pump
Warning!
Falling loads
Observe the following instructions when transporting the pump:
► To transport the pump, use suitable lifting gear with sufficient carrying
capacity.
► Make sure that there are no persons present under suspended loads.
► Make sure that the pump is horizontally aligned when lifting.
► Attach the rope to suitable anchor points.
► Never fasten a rope to the pump housing or the suction/discharge port!
► For version with casing: Remove the stainless steel casing before
transport.
4.4 Attachment points for lifting loads
Fig.3: Attachment points
4.5 Storage of the pump
Follow the following instructions for the storage of the pump:
•The maximum storage period is two years.
•In case of frost risk, drain the pump completely. Protect the pump from low
temperatures.
•If the pump is not used immediately, proper storage conditions are as
important for later operation as careful installation and proper maintenance.
•During storage, the pump should be turned by hand at least once a month.
Parts such as shaft and bearings should change their position.
Transport and Storage
Special personnel qualification for transport and storage
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