GEA NEMA/3-A User manual

Hygienic Pumps
GEA Hilge TP (NEMA / 3-A)
Operating instruction (Translation from the original language)
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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
Niederlassung der GEA Tuchenhagen GmbH
hereinafter referred to as Manufacturer This restriction also applies to the
drawings and diagrams included in the documentation.
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TABLE OF CONTENTS
1 General Information 5
1.1 Information on the Document 5
1.1.1 Binding Character of These Operating Instructions 5
1.1.2 Notes on the Illustrations 5
1.1.3 Symbols and Highlighting 5
1.2 Manufacturer address 6
1.3 Customer service 6
1.4 Confirmation of FDA compliance 7
2 Safety 8
2.1 Intended use 8
2.1.1 Requirements for operation 8
2.1.2 Improper operating conditions 8
2.2 Operator’s Duty of Care 8
2.3 Subsequent changes 9
2.4 General safety instructions and dangers 9
2.4.1 Principles for safe operation 10
2.4.2 Environmental Protection 10
2.4.3 Electrical Equipment 10
2.5 Supplementary Regulations 11
2.6 Qualification of Personnel 11
2.7 Safety equipment 12
2.7.1 Signs 12
2.8 Residual dangers 13
2.9 Danger zones 14
3 Description 16
3.1 Design 16
3.2 Functional description 16
3.3 Motor versions 17
4 Transport and storage 18
4.1 Storage conditions 18
4.2 Transport 18
4.2.1 Scope of supply 19
5 Technical data 20
5.1 Type plate 20
5.2 Technical data 20
5.2.1 General operating data - nominal values 20
5.2.2 Materials - product contacting 21
5.2.3 Motor 21
5.2.4 Specific operating data - nominal values 22
5.3 Resistance of Sealing Materials 23
5.4 Lubricants 24
5.5 Weights 25
5.6 Torques 26
6 Assembly and installation 28
6.1 Safety instructions 28
6.2 Setting up the pump 28
6.2.1 Settings for 3-A setup 28
6.3 Installing the pipelines 29
6.4 Connecting the motor 30
6.5 Checking the direction of rotation 31
6.6 Checking the sealing liquid 32
6.6.1 Self-draining seal cartridge 32
7 Start-up 33
7.1 Safety instructions 33
7.2 Notes on commissioning 33
8 Operation and control 34
8.1 Safety instructions 34
9 Cleaning 35
9.1 Cleaning 35
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9.1.1 Cleaning Process Examples 35
9.1.2 Cleaning effect 35
9.2 Steam sterilization 36
9.3 Manual exterior cleaning 36
10 Maintenance 37
10.1 Safety instructions 37
10.2 Inspections 38
10.2.1 Replacement of O-rings 38
10.3 Maintenance intervals 38
10.4 Prior to disassembly 39
10.5 Disassembly 39
10.5.1 Removing the pump cover and impeller 39
10.5.2 Removing the single-acting mechanical seal EW 41
10.5.3 Removing the single-acting flushed mechanical seal QU 42
10.5.4 Removing the double-acting mechanical seal DW 44
10.5.5 Removing the motor 45
10.6 Maintenance 46
10.6.1 Single-acting mechanical seal EW 46
10.6.2 Single-acting mechanical seal QU (A) 46
10.6.3 Double-acting mechanical seal DW (A) 46
10.7 Prior to installation 47
10.7.1 Cleaning the components before assembly 47
10.8 Installation 47
10.8.1 Installing the motor 47
10.8.2 Installing the mechanical seal 48
Installing the single slide-ring packing EW 49
Installing the single-acting mechanical seal, flushed QU 50
Installing the double-acting mechanical seal DW 51
10.8.3 Converting the mechanical seal 52
Convert single-acting mechanical seal EW to mechanical seal, flushed QU 52
Convert single-acting mechanical seal EW to double-acting mechanical seal DW 53
10.8.4 Adjusting the axial gap 54
10.8.5 Installing the pump cover 56
11 Drainage valve VTP 57
11.1 Intended use - drainage valve VTP 57
11.2 Retrofitting of the drain valve VTP 57
11.3 Troubleshooting - drainage valve VTP 57
11.4 Maintenance - drainage valve VTP 58
11.5 Technical data - drainage valve VTP 60
12 Alarms 62
12.1 Malfunctions and remedies 62
13 Decommissioning 63
13.1 Safety instructions 63
13.2 Disposal 63
13.2.1 General notes 63
14 Reworking of EW - QU 64
15 Appendix 65
15.1 Lists 65
15.1.1 Abbreviations and terms 65
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1 General Information
1.1 Information on the Document
The present Operating Instructions are part of the user information for the
product. The Operating Instructions contain all the information you need to
transport, install, commission, operate and carry out maintenance for the product.
1.1.1 Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the
operator of the product and to all persons who work on or use the product
regarding the procedures to follow.
Carefully read these Operating Instructions before starting any work on or using
the product. Your personal safety and the safety of the product can only be
ensured if you act as described in the Operating Instructions.
Store the Operating Instructions in such a way that they are accessible to the
operator and the operating staff during the entire life cycle of the product. When
the location is changed or the product is sold make sure you also provide the
Operating Instructions.
1.1.2 Notes on the Illustrations
The illustrations in these Operating Instructions show the product in a simplified
form. The actual design of the product can differ from the illustration. For detailed
views and dimensions of the product please refer to the design documents.
1.1.3 Symbols and Highlighting
In these Operating Instructions, important information is highlighted by symbols
or special formatting. The following examples illustrate the most important types
of highlighting.
Danger
Warning: Fatal Injuries
Failure to observe the warning can result in serious damage to health, or
even death.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Warning: Explosions
Failure to observe the warning can result in severe explosions.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
General Information
Information on the Document
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Warning!
Warning: Serious Injuries
Failure to observe the warning can result in serious damage to health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Caution!
Warning: Injuries
Failure to observe the warning can result in minor or moderate damage to
health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Notice
Warning: Damage to Property
Failure to observe the warning can result in serious damage to the
component or in the vicinity of the component.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Carry out the following steps: = Start of a set of instructions.
1. First step in a sequence of operations.
2. Second step in a sequence of operations.
®Result of the previous operation.
®The operation is complete, the goal has been achieved.
Hint!
Further useful information.
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)
General Information
Manufacturer address
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Phone [phone] (Service)
[email protected]
1.4 Confirmation of FDA compliance
Fig.1
General Information
Confirmation of FDA compliance
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2 Safety
2.1 Intended use
GEA Hilge Centrifugal Pumps TP with NEMA standard motor are suitable for the
proper hygienic conveyance of biologically complex and expensive liquids up to a
viscosity of 1000 mPas = 1000 cP.
Therefore they can be used as product pumps in the food industry,
pharmaceutical industry and as cleaning agent pumps in CIP cleaning circuits.
The motors used by GEA have limited axial clearance.
Fig.2
Only use pumps with the proper certification in the explosion hazardous areas.
Additional requirements apply in explosive atmosphere areas.
Hint!
The manufacturer is not liable for damage caused by improper use of
the pump. The risk of such misuse lies entirely with the operator of the
facility.
2.1.1 Requirements for operation
Prerequisites for trouble-free, safe operation of the pump are proper transport
and storage as well as proper installation and assembly. The intended use also
includes compliance with the operating, maintenance and service requirements.
2.1.2 Improper operating conditions
The operational safety of the pump can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
The operation of the pump is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the pump.
•Damage to the pump has been detected.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
The operating company of the pump has a special responsibility for the proper
and safe handling of the pump within their company. Only use the pump when it
is in perfect operating condition in order to prevent danger to persons and
property.
Safety
Intended use
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This operating manual contains information that you and your employees need
for safe operation over the life of the pump. Be sure to read these Operating
Instructions carefully and ensure that the measures described here are observed.
The operator's duty of care includes planning the necessary safety measures and
monitoring that these measures are observed. The following principles apply:
•Only qualified personnel may work on the pump.
•The operator must authorize personnel to carry out the relevant tasks.
•Order and cleanliness must be maintained at the work stations and in the
entire area surrounding the pump.
•Personnel must wear suitable work clothing and personal protective
equipment. As the operator of the facility make sure that work clothing and
personal protective equipment are used.
•Inform personnel regarding any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aid representative on call during the operation. This
person must be able to initiate any necessary first-aid measures in case of an
emergency.
•Clearly define procedures, competences and responsibilities for those
working in the area of the pump. All personnel must be aware of the actions to
be taken in the event of an emergency. Be sure to instruct the personnel at
regular intervals.
•The signs on the pump must always be complete and easy to read. Check,
clean and replace the signs as necessary at regular intervals.
•Observe the Technical Data specified and the limits of use!
Hint!
Carry out regular checks. This way you can ensure that these
measures are actually observed.
2.3 Subsequent changes
No technical modifications should ever be made to this pump. Otherwise, you will
have to re-conduct the conformity assessment/risk assessment in accordance
with applicable national directives.
Only original spare parts from GEA should be installed. This ensures that the
pump is always operating properly and efficiently.
2.4 General safety instructions and dangers
The pump is safe to operate. It was built according to the current state of science
and technology.
Nevertheless, dangers can arise from the pump, if:
•the pump is not used as intended,
•the pump is used improperly,
Safety
Subsequent changes
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•the pump is operated under impermissible conditions.
2.4.1 Principles for safe operation
Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the personnel.
The following principles apply for safe operation of the pump:
•The instructions must be complete and kept in proper legible condition for
anyone within the operating area of the pump.
•Only use the pump for its intended purpose.
•The pump must be in working order and function properly. Check the
condition of the pump before starting work and at regular intervals.
•Wear tight fitting work clothes for all types of work on the pump.
•Make sure that no one can get injured from the parts of the pump.
•Report malfunctions or detectable changes to the pump immediately to the
person in charge.
•Never touch the pipelines and the pump when they are hot! Avoid opening the
pump if the process equipment is not drained or still under pressure.
•Observe the accident prevention regulations and all local regulations.
2.4.2 Environmental Protection
Harm to the environment can be avoided by safety-conscious and proactive
behaviour of the staff.
For environmental protection the following principles apply:
•Substances harmful to the environment must not be discharged into the
ground or the sewage system.
•Always observe the pertinent regulations relating to waste avoidance,
disposal and utilization.
•Substances harmful to the environment must be collected and stored in
suitable containers. Clearly mark the containers.
•Dispose of lubricants as hazardous waste.
2.4.3 Electrical Equipment
For all work on electrical equipment, the following principles apply:
•Access to electrical equipment should only be allowed to qualified
electricians. Always keep unattended switch cabinets locked.
•Modifications of the control system can affect the safe and reliable operation.
Modifications are only permitted with the express permission of the
manufacturer.
•After completion of all work, check that the protective devices are fully
functional.
Safety
General safety instructions and dangers
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2.5 Supplementary Regulations
In addition to the instructions in this documentation the following also has to be
observed:
•pertinent accident prevention regulations,
•generally accepted safety rules,
•national regulations applicable in the country of use,
•work and safety instructions applicable in the facility,
•installation and operating regulations for use in potentially explosive areas.
2.6 Qualification of Personnel
This section provides information on how the personnel working on the pump
must be trained.
Operating and maintenance personnel must
•have the necessary qualification to carry out their tasks,
•be instructed with regard to possible dangers,
•know and observe the safety instructions given in the documentation.
Only allow qualified electricians to carry out work on the electrical equipment or
have a qualified electrician supervise the work.
Only allow specially trained personnel to carry out work on an explosion-
protected system. Observe the corresponding national standards for gases and
dust when working on an explosion-protected system.
The following minimum qualifications are required:
•Training as a specialist for working independently on the pump
•Adequate instruction to work on the pump under the supervision and
guidance of a trained specialist
Each employee must meet the following requirements to work on the pump:
•Personal suitability for the respective task.
•Sufficient professional qualification for the respective task.
•Received instruction about the functionality of the pump.
•Received instruction about operating sequences on the pump.
•Familiar with the safety devices and their function.
•Familiar with these Operating Instructions, especially with the safety
instructions and the information which is relevant for the task on hand.
•Familiar with the basic regulations with regard to occupational health and
safety and accident prevention. When working with the pump, a distinction is
made between the following user groups:
Safety
Supplementary Regulations
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User groups
Personnel Qualifications
Operating personnel Adequate instruction and sound knowledge in the following areas:
•Functionality of the pump
•Operating sequences on the pump
•What to do in case of an emergency
•Lines of authority and responsibilities with respect to the task
Maintenance personnel Appropriate training and a sound knowledge of the structure and
functionality of the pump.
Sound knowledge in the following areas:
•Mechanical equipment
•Electrical equipment
•Pneumatic system
Authorization with regard to safety engineering standards to carry
out the following tasks:
•Setting devices into operation
•Earthing of devices
•Marking of devices
The corresponding certification must be available for work on
certified machines.
2.7 Safety equipment
2.7.1 Signs
Hazardous locations on the pump are marked by warning signs, prohibition signs
and mandatory signs.
The signs and instructions on the pump must always be legible. Any illegible
signs must be replaced immediately.
Safety
Safety equipment
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Signs on the pump
Sign Meaning
Fig.3
General hazard warning
Fig.4
Warning Crushing
Fig.5
Explosive atmosphere hazard warning
2.8 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel and by wearing personal protective equipment.
Residual hazards on the pump and preventative measures
Danger Cause Measure
Danger to life Unintentional switch-on
of the pump
Effectively disconnect all
components, effectively
prevent switch-on.
Electric power Observe the following
safety rules:
1. Isolate from the
power supply.
2. Take appropriate
measures to prevent
switch on.
3. Test absence of
voltage.
4. Earthing and short-
circuiting.
5. Cover or safeguard
any adjacent live
parts.
Safety
Residual dangers
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Residual hazards on the pump and preventative measures
Danger Cause Measure
Danger of injury Danger presented by
moving or sharp-edged
parts
The operator must
exercise caution and
prudence.
For all work:
•Wear suitable work
clothing.
•Never operate the
machine if the cover
panels are not
correctly fitted.
•Never open the cover
panels during the
operation.
•Never reach into
openings.
Wear protective clothing
in the entire area of the
pump as a preventative
measure:
•Protective gloves
•Safety shoes
Environmental damage Operating materials with
properties which are
harmful to the
environment
For all work:
•Collect lubricants in
suitable containers.
•Dispose of lubricants
in accordance with
the pertinent
regulations.
2.9 Danger zones
Please observe the following notes:
Safety
Danger zones
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Fig.6
•In case of malfunction, take the pump out of service (separate from the power
supply) and secure against restarting.
•Never touch the lantern (5), the fan housing of the motor (60), the suction (S)
or the pump discharge nozzle (D) while the pump is running. Fingers can be
crushed or cut off.
•Switch off the pump during all maintenance, repair and service work and
secure the it against unintentional restart.
•After maintenance, never forget to remove the hexagon socket screwdriver
(B) from the cylinder screw on the shaft.
•Only allow a qualified electrician to carry out any work on the electrical power
supply.
•Regularly check the electrical equipment of the pump. Immediately remedy
loose connections and molten cables.
•If work on live parts cannot be avoided, call in a second person, who can
operate the main switch in case of an emergency.
•The housing sockets have very sharp edges. Wear suitable protective gloves
when transporting and installing the pump.
Safety
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3 Description
3.1 Design
Fig.7: Pump TP - Standard
The pump consists of the following parts:
•Pump housing (4), pump cover (3), motor stool (5)
•Impeller (1), shaft (7), cap nut (9)
•A three-phase asynchronous motor (60)
•Cup-shaped feet carrier (15)
The pump shaft (7) is attached on the shaft end of the three-phase asynchronous
motor.
The pump shaft is fixed axially by 2 cylinder screws (51).
The motor stool (5) allows the connection of different motor sizes to the pump.
The motor stool (5) connects the motor to the pump housing (4). It has 2 holes to
indicate leakage.
Depending on the design, the pump has a single-acting (EW), a single-acting
flushed (QU) or a double-acting mechanical seal (DW).
The slide-ring of the mechanical seal is carried along with the impeller by a pin.
The impeller is installed between the pump housing and the pump cover.
The height and the horizontal orientation of the pump are set with 4 height-
adjustable cup-shaped feet.
If necessary, the pump can be equipped with a stainless steel hood to protect the
motor.
3.2 Functional description
Description
Design
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The centrifugal pump TP has normal suction. It requires the constantly supply of
fluid on the suction nozzle. The impeller with its blades curved backward, rotates
in the pump at the speed of the motor. The rotation of the impeller transmits
energy in the form of centrifugal forces and speed increases to the conveying
medium which is then pumped from the discharge nozzle.
The suction nozzle is aligned radially and centrically with the body of the pump.
The discharge nozzle is tangential, generally upwards, otherwise in 45 ° angles
on the pump body.
3.3 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.
–General purpose motors
These motor variants are used in all applications that are not subject to strict
hygiene regulations.
Description
Motor versions
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4 Transport and storage
4.1 Storage conditions
The storage facility must be covered and well-ventilated. Avoid high humidity.
The pump must be drained at temperatures below the freezing point.
4.2 Transport
Fig.8
For transport, the following principles apply:
•The packaging units/pumps may only be transported with appropriate hoists
and lifting devices. Observe the graphic symbols on the packaging.
•The pump must be transported as shown in the figure.
•Observe the pictograms on the package.
•Transport the pump carefully to prevent damage due to external force or
careless loading and unloading.
•Only qualified personnel are allowed to transport the pump.
•Movable parts must be properly secured.
•Only use approved, fully functional load lifting devices and lifting accessories
which are suitable for the intended purpose. Observe the maximum load-
bearing capacities.
•Secure the pump against slipping. Observe the weight of the pump and the
center of gravity position.
•Under no circumstances should anyone stand under a suspended load.
Transport and storage
Storage conditions
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•Transport the pump carefully. Do not grip sensitive parts of the unit to lift or
push the unit or to support yourself. Avoid putting the unit down with a jerk.
4.2.1 Scope of supply
After taking delivery of the pump, check if
•the details on the type plate correspond to the data in the order and delivery
documents,
•the equipment is complete and all components are in good order.
Externally visible transport damage and / or missing packages must be indicated
immediately on the freight note with the delivering forwarder. Written recourse
must be taken immediately against the freight forwarder by the recipient and GEA
must be informed about the process. Claims must be submitted within 6 days to
the freight forwarder for transport damage that is not recognized immediately.
The recipient will bear the cost of any damage claimed beyond this point.
Transport and storage
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5 Technical data
5.1 Type plate
The identification plate is used to distinctly identify the pump.
GEA Tuchenhagen GmbH
Am Industriepark 2-10, 21514 Büchen, Germany
Type
Motor
Order
Serial
Year
Fig.9: Type plate sample
The type plate provides the following key data:
Key data of the pump
Type Pump type and configuration
Motor Motor type
Order Order number and year of manufacture
Serial Serial number
5.2 Technical data
Refer to the following tables for the key technical data:
5.2.1 General operating data - nominal values
Sealing liquid pressure
(type DW, double-acting
mechanical seal)
min. 2 bar (29 psi)
Max. 3 bar (43.5 psi) over operating pressure
Sealing liquid
temperature
(type DW, double-acting
mechanical seal)
up to 60 °C (140 °F)
Max. 70 °C (158°F) temporarily
Sealing liquid pressure
(type QU, single-acting
mechanical seal flushed
with lip seal for barrier
liquid)
up to 2000 rpm: Max. 0.35 bar (5 psi)
up to 3500 rpm: Max. 0.2 bar (2.9 psi)
(according to DIN 3760)
Technical data
Type plate
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