GEA Hilge HYGIA ADAPTA User manual

Hygienic Pumps
GEA Hilge HYGIA ADAPTA (US) - Version C - Version D
Operating instruction (Translation from the original language)
BA.H2A.ADY.002.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.
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.
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
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–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
2 Safety 10
2.1 Intended use 10
2.1.1 Pumped fluids 10
2.1.2 Minimum flow rate 10
Minimum flow rates in explosive atmospheres 10
2.1.3 Connections and piping 10
2.1.4 Switching frequency 10
2.1.5 Types 10
2.1.6 Hygiene classification 10
2.2 Safety precautions in these operating instructions 11
2.3 Explanation of the safety symbols used 12
2.4 Safety instructions for the company/operator 12
2.4.1 Dangers of non-compliance with safety information 13
2.4.2 Safety-conscious work behaviour 13
2.5 Unauthorised modification and ordering of spare parts 13
2.6 Staff qualifications and training 14
2.7 Safety equipment 14
3 Description 15
3.1 Pump overview 15
3.2 Description 15
3.2.1 Standard version applications 15
3.2.2 Hygienic design applications 16
3.3 Pump name 16
3.4 Type plate 16
3.5 Motor versions 16
4 Transport and Storage 18
4.1 Special personnel qualification for transport and storage 18
4.2 Safety precautions for transport and storage 18
4.3 Dimensions / weights 19
4.4 Unpacking the pump 20
4.5 Disposal of packaging material 21
5 Technical data 22
5.1 Serial number 22
5.2 Performance data 22
5.3 Noise emissions 22
5.4 Maximum operating temperatures 23
5.5 Maximum operating pressure 23
5.6 Resistance of Sealing Materials 23
6 Assembly and installation 25
6.1 Safety precautions for setup, installation, and connection 25
6.1.1 Mechanical seals in tandem arrangement 27
6.1.2 Mechanical seals in back-to-back arrangement 27
6.1.3 Vertically installed pumps 27
6.2 Special personnel qualification 27
6.3 Setup, installation, and connection 27
6.3.1 Checking smooth running of the impeller 28
6.3.2 Setting up and aligning the pump unit 28
6.3.3 Installation in the piping system 29
Space requirements 29
Noise and vibration damping 30
6.3.4 Using the mechanical seal 32
6.3.5 Flush connections for double mechanical seals (optional) 33
Flushing fluid (optional) 33
Double mechanical seals (optional) 33
Defective shaft seal 36
6.4 Electrical connection 36
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6.4.1 Connect NEMA motors 36
6.4.2 Frequency converter operation 36
6.4.3 Checking the direction of rotation after connecting 36
6.4.4 Earthing 37
Earthing the motor 37
Earthing the machine pad support 37
7 Commissioning 38
7.1 Special personnel qualification 38
7.2 Safety instructions for commissioning 38
7.3 Commissioning / initial startup 38
7.3.1 Checking conditions of use 38
7.3.2 Commissioning of the pump 38
7.3.3 Functional testing of the mechanical seal 39
8 Cleaning 40
8.1 Special personnel qualification 40
8.2 Safety instructions 40
8.3 CIP 41
8.4 SIP 42
8.5 Manual exterior cleaning 42
9 Maintenance / servicing 43
9.1 Safety instructions for maintenance and repair 43
9.2 Special personnel qualification 43
9.3 Pump maintenance 43
9.3.1 Inspections 43
Replacement of O-rings 43
9.3.2 Maintenance intervals 44
9.4 Maintenance of the ADAPTA bearing 44
9.4.1 Bearing carrier structure sizes 1 and 2 44
9.4.2 Bearing structure carrier size 3 45
9.4.3 Bearing replacement 45
9.4.4 Premature bearing replacement 45
9.4.5 Grease filling 46
Roller bearing greases 46
9.5 Maintenance of the motor 47
10 Malfunctions / repairs 48
10.1 Special personnel qualification 48
10.2 Safety instructions 48
10.3 Malfunctions and remedies 49
10.4 Repair 50
10.4.1 Repair order 50
10.4.2 GEA Hilge assembly tool kit 52
Contents and use 52
10.4.3 Parts overview 53
10.4.4 Parts overview of ADAPTA bearing support sizes 1 and 2 54
10.4.5 Parts overview ADAPTA bearing support size 3 55
10.4.6 Parts overview of coupling and motor 56
10.4.7 Installation instructions 57
Cleaning the components before assembly 57
10.4.8 Installing ADAPTA bearing supports size 1 and 2 58
10.4.9 Installing ADAPTA bearing support BG 3 63
10.4.10 Installing single mechanical seal 69
10.4.11 Determining gap size on HYGIA 70
10.4.12 Installing single conical spring mechanical seal 72
10.4.13 Installing the single mechanical seal - spring encapsulated (hygiene) 74
10.4.14 Installing double mechanical seal 76
10.4.15 Installing tandem double mechanical seal 81
10.4.16 Installing double mechanical seal in back-to-back position 83
10.4.17 Installing impeller and housing 85
10.4.18 Installing the wear inserts 91
11 Decommissioning 92
11.1 Special personnel qualification 92
11.2 Safety instructions 92
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11.3 Temporary decommissioning 92
11.4 Disposal 92
12 Appendix 93
12.1 Certificate of non-objection 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 12.
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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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.
2.1.6 Hygiene classification
The pump is suitable for hygienic processes. It must not be used in aseptic
processes.
Safety
Intended use
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2.2 Safety precautions in these operating instructions
Read the safety precautions!
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.
Safety
Staff qualifications and training
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3 Description
3.1 Pump overview
0156.00
0103.00
0153.00
0180.00
0801.00
0680.000330.00
Fig.1: GEA Hilge HYGIA ADAPA
0103 Annular casing
0153 Suction port
0156 Discharge port
0180 Combi foot
0330 Bearing housing
0801 Stainless steel shroud
0801 Motor
3.2 Description
The pump is a normal-priming, single-stage centrifugal pump in system block
design. The versions selected versions comply with the 3-A standard 02-11. The
material quality 1.4404 or 1.4435 (AISI 316 / 316L) Fe ≤ 1% and the respective
version standard is implemented in accordance with the order and, if desired,
fully certified
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)
Description
Pump overview
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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 HYGIA N 1 / R A HU ...
Pump name Size Number of
stages Version Design type Assembly Additional information
1 = 1-stage D=USA
3-A
Pump in
ADAPTA-
BLOC
design with
bearing
support and
standard
motor
Horizontal
assembly on
3-A dome
base
see
catalogue
No. ...
3.4 Type plate
GEA Hilge
Niederlassung der Tuchenhagen GmbH
Hilgestrasse - D - 55294 Bodenheim
Pump-Type:
Ser.-No.: 990012340001
P/N: 99001234
Q: 50 USgpm H: 60 ft n: 3450 rpm
P: 5 hp
TAG No.:
YOM: 12/2017 Made in Germany
GEA Hilge HYGIA I-1/D-AHUO0-IA0160
OFAF22-211-EEMSE-D
Fig.2: Type plate
Pump type: Pump name P: Motor rating
Serial No.: Pump number n: Speed
P/N: Pump number TAG No.:customer name
Q: Flow rate YOM: Year of manufacture
H: Delivery head
Note: The type plate may differ from the presented layout.
3.5 Motor versions
–Washable motors (wash down)
These motor variants are used in applications that are subject to strict
hygienic regulations, in which nucleation and corrosion must be avoided and
in which the pumps (installations) must be cleaned cyclically.
Description
Pump name
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–General purpose motors
These motor variants are used in all applications that are not subject to strict
hygiene regulations.
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
Warning!
Falling loads
Danger from falling loads.
► 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.
Warning!
Wrong attachment points!
► Attach the rope to suitable anchor points.
► Never fasten a rope to the pump housing or the suction/pressure port!
► For version with casing: Remove the stainless steel casing before
transport.
Fig.3: Anchor points (example)
Storage of the pump
Caution!
Frost
Risk due to external conditions.
► In case of frost risk, drain the pump completely.
If the pump is not used immediately, proper storage conditions are as important
for later operation as careful installation and proper maintenance.
Protect the pump from cold, moisture and dust, as well as against mechanical
influences.
Qualified personnel is required for proper installation and maintenance.
Transport and Storage
Special personnel qualification for transport and storage
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4.3 Dimensions / weights
Weights HYGIA ADAPTA on motor base | 2 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1.5 143T 39.5 87.1 BG1
2 145T 43.2 95.2 BG1
3 182T 55.8 123.0 BG1
5 184T 62.6 138.0 BG1
5 184T 77.0 169.8 BG2
7.5 213T 90.1 198.6 BG1
7.5 213T 101.5 223.8 BG2
10 215T 114.6 252.6 BG2
15 254T 120.7 266.1 BG2
20 256T 137.2 302.5 BG2
25 284TS 261.3 576.1 BG2-AD3
30 286TS 275.3 606.9 BG2-AD3
Weights HYGIA ADAPTA on motor base | 4 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1 143T 41.2 90.8 BG1
1.5 145T 42.2 93.0 BG1
2 145T 44.2 97.4 BG1
3 182T 77.8 171.5 BG2
5 184T 73.8 162.7 BG2
7.5 213T 95.8 211.2 BG2
10 215T 100.5 221.6 BG2
Weights HYGIA ADAPTA on spherical stand | 2 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1.5 143T 43.4 95.6 BG1
2 145T 47.1 103.8 BG1
3 182T 59.5 131.1 BG1
5 184T 68.3 150.5 BG1
5 184T 82.7 182.3 BG2
7.5 213T 95.8 211.2 BG1
7.5 213T 107.2 236.3 BG2
10 215T 120.3 265.2 BG2
15 254T 126.4 278.6 BG2
20 256T 142.9 315.0 BG2
25 284TS BG2-AD3
30 286TS BG2-AD3
Transport and Storage
Dimensions / weights
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Weights HYGIA ADAPTA on spherical stand | 4 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1 143T 45.1 99.4 BG1
1.5 145T 46.1 101.6 BG1
2 145T 48.1 106.0 BG1
3 182T 83.5 184.1 BG2
5 184T 79.5 175.2 BG2
7.5 213T 101.5 223.7 BG2
10 215T 106.2 234.1 BG2
Weights HYGIA ADAPTA on 3A-assembly | 2 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1.5 143T 44.3 97.7 BG1
2 145T 48.0 105.8 BG1
3 182T 58.6 129.2 BG1
5 184T 67.3 148.5 BG1
5 184T 109.9 242.4 BG2
7.5 213T 95.7 211.1 BG1
7.5 213T 112.7 248.6 BG2
10 215T 125.9 277.5 BG2
15 254T 144.2 317.8 BG2
20 256T 160.7 354.2 BG2
25 284TS 274.0 604.0 BG2-AD3
30 286TS 288.0 634.9 BG2-AD3
Weights HYGIA ADAPTA on 3A-assembly | 4 pole
P2
[HP]
NEMA-
frame size
Total Weight
[kg]
Total Weight
[lb] BG1/2
1 143T 46.0 101.4 BG1
1.5 145T 47.0 103.6 BG1
2 145T 49.0 108.0 BG1
3 182T 86.3 190.3 BG2
5 184T 82.2 181.3 BG2
7.5 213T 107.0 236.0 BG2
10 215T 111.8 246.4 BG2
4.4 Unpacking the pump
All of our pumps leave our warehouse properly packaged to avoid damage in
transit.
Should you nevertheless find any damage after cautious unpacking and exact
inspection of the shipment, immediately notify the carrier (railway, post, freight
forwarder, shipping company). Make claims for damages. The transport risk
passes to the customer once the shipment has left our warehouse.
Transport and Storage
Unpacking the pump
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