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Alfalaval LKHex UltraPure 10 Instruction Manual

Centrifugal pump
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Instruction Manual
LKHex UltraPure Centrifugal Pump
100000157-EN1
Original manual
2018-02
3001-0064

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  • Page 1 Instruction Manual LKHex UltraPure Centrifugal Pump 3001-0064 100000157-EN1 2018-02 Original manual...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. EU Declaration of Conformity ............... 1.1. ATEX Directive 2014/34/EU ..............1.2. ATEX Marking ..................2. Safety ....................2.1.

  • Page 4: Eu Declaration Of Conformity

    1 EU Declaration of Conformity Alfa Laval certificate no.: 9612-9609-01 X This declaration of conformity is issue under sole responsibility of the manufacturer: Alfa Laval Kolding A/S Company Name Albuen 31, 6000 Kolding, Denmark Address +45 79 32 22 00 Phone No.

  • Page 5: Atex Directive 2014/34/Eu

    1 EU 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, vapours and dusts. Centrifugal 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 3.

  • Page 6: Atex Marking

    1 EU Declaration of Conformity 1.2 ATEX Marking Name plate example: Manufacturer: Alfa Laval, Albuen 31, Kolding, DK-6000 Pump Type LKHex UP-20 Serial No. 123456 Year 2018 Specification Dia:163 11.0kW 50Hz SSS II 2 G Ex h IIB T4 Gb Ta -20C to +35C Shroud not allowed 163 11.0kW 50Hz SSS Shaft seal type (single shaft seal)
  • Page 7 1 EU Declaration of Conformity Name plate position 3001-0063 See marking options in chapter 2.3 Special conditions for safe use , table A.

  • Page 8: Safety

    2 Safety Unsafe practices and other important information are emphasised in this manual. Warnings are emphasised by means of special signs. Always read the manual before using the pump! 2.1 Important information WARNING Indicates that special procedures must be followed to avoid serious personal injury. CAUTION Indicates that special procedures must be followed to avoid damage to the pump.

  • Page 9: Special Conditions For Safe Use

    2 Safety All warnings in the manual are summarised in this section. Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided. 2.3 Special conditions for safe use General warnings. Always read chapter 4.2 Operating conditions. Never run the pump with neither the suction side nor the pressure side blocked.
  • Page 10 2 Safety All warnings in the manual are summarised in this section. Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided. Requirements for measurements on the process media There are two principles of temperature measurements of the process media: A.
  • Page 11 2 Safety All warnings in the manual are summarised in this section. Pay special attention to the instructions below so that severe personal injury and/or damage to the pump are avoided. “b1” control system requirements Measurement system shall be chosen according to EN-ISO 80079-37. Always test and validate the control system before production start-up.

  • Page 12: Safety Precautions

    2 Safety 2.4 Safety precautions General considerations To prevent hazardous reactions between the processed fluid and the materials of construction, the materials of construction must be suitable for the application. The auxiliary equipment chosen for the application must be suitable. Education Personnel installing, operating or carrying out maintenance on the pump or any sub-component must have the necessary knowledge about the LKHex UltraPure pump range.
  • Page 13 2 Safety Maintenance Always read the chapter 5 Maintenance before servicing the pump. Always make sure that the specifications in chapter 4 Operation are met before the pump is put back into operation. Always refer to the pump serial no. on the name plate when ordering spare parts to ensure correct spares. Always read the technical data thoroughly.

  • Page 14: Installation

    3 Installation 3.1 Unpacking/delivery Step 1 Check the delivery for: 1. Complete pump. 2. Delivery note. 3. Motor instructions. 4. Instructions for flushing set, IF ORDERED! Always use a lifting crane when handling the pump (see 6 Technical data). CAUTION Alfa Laval cannot be held responsible for incorrect unpacking.
  • Page 15 3 Installation Step 4 Remove the shroud before lifting! Always remove the shroud, if fitted, before lifting the pump. 3007-0092 Step 5 Do NOT use eyebolt in casing to lift the pump. The ONLY LKH UltraPure-60 and LKH UltraPure-70 eyebolt is for casing removal only. 3007-0093...

  • Page 16: Installation

    3 Installation Read the instructions carefully and pay special attention to the warnings! Always check the pump before operation. - See pre-use check in section 3.3 Pre-use check. The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.
  • Page 17 3 Installation Read the instructions carefully and pay special attention to the warnings! Always check the pump before operation. - See pre-use check in section 3.3 Pre-use check. The large pump sizes are very heavy. Alfa Laval therefore recommends the use of a lifting crane when handling the pump.

  • Page 18: Pre-Use Check

    3 Installation Read the instructions carefully and pay special attention to the warnings! LKH UltraPure is not supplied with an impeller screw as standard but can be supplied with one. Check the direction of rotation of the impeller before operation. - See the indication label on the pump.

  • Page 19: Recycling Information

    3 Installation 3.4 Recycling information • Unpacking - Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps. - Wood and cardboard boxes can be reused, recycled or used for energy recovery. - Plastics should be recycled or burnt at a licensed waste incineration plant. - Metal straps should be sent for material recycling.

  • Page 20: Operation

    4 Operation Read the instructions carefully and pay special attention to the warnings! 4.1 Important check and monitoring during operation Daily checks - Shaft seal (SSS and DMS) If leakage from the shaft seal can lead to dangerous situations, daily visual inspection for leakage is recommended. - If leakage is detected the risk should be evaluated and maintenance of the seal should be planned accordingly.

  • Page 21: Operating Conditions

    If VFD is used, the motor should be oversized by 10 % with regards to power output. Pump unit: Maximum inlet pressure LKHex UltraPure 10-70, 50/60 Hz 500 kPa (5 bar) (72 psi) Maximum product media temperature during normal operation for specific elastomers...

  • Page 22: Operation/Control

    4 Operation Read the instructions carefully and pay special attention to the warnings! 4.3 Operation/control Step 1 Always read the technical data thoroughly. See chapter 6 Technical data CAUTION Alfa Laval cannot be held responsible for incorrect operation/control. Step 2 Danger of burns! Never touch the pump or the pipelines when pumping hot liquids or when sterilising.
  • Page 23 4 Operation Read the instructions carefully and pay special attention to the warnings! Step 5 O: Outlet Double mechanical shaft seal: 1. Connect the inlet of the flushing liquid correctly. I: Inlet 2. Read instructions for pressure, temperature and flow limitations, in 4.2 Operating conditions.

  • Page 24: Trouble Shooting

    4 Operation Pay attention to possible faults. Study the instructions carefully. 4.4 Trouble shooting NOTE! Study the maintenance instructions carefully before replacing worn parts. Problem Remedy Cause/result Overloaded motor - Pumping of viscous liquids - Larger motor or smaller impeller - Pumping of high density liquids - Low outlet pressure (counter pressure) - Higher counter pressure (throttling) - Lamination of precipitates from the...

  • Page 25: Recommended Cleaning

    4 Operation The pump is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic soda. = Nitric acid. 4.5 Recommended cleaning Step 1 Caustic danger! Always handle lye and acid with great care.

  • Page 26: Maintenance

    5 Maintenance Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings! Always keep spare shaft seals and rubber seals in stock. See separate motor instructions. 5.1 General maintenance Step 1 Always read the technical data thoroughly. (See chaper 6 Technical data) Always use Alfa Laval genuine spare parts.
  • Page 27 5 Maintenance Maintain the pump carefully. Study the instructions carefully and pay special attention to the warnings! Always keep spare shaft seals and rubber seals in stock. See separate motor instructions. Rubber seals Motor bearings Shaft seal Preventive maintenance Replace after 12 months: Replace when replacing the (one-shift) Complete shaft seal shaft seal...

  • Page 28: Dismantling Of Pump/Shaft Seals

    5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. : Relates to the shaft seal. 5.2 Dismantling of pump/shaft seals Step 1 Unscrew cap nuts (24) and remove washers (24a) and pump casing (29).
  • Page 29 5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. : Relates to the shaft seal. Step 5 1. Pull off the O-ring (26) from back plate (25). 2. Unscrew nuts (20) and remove washers (21) and the back plate. 3007-0101 Step 6 Use the tool...
  • Page 30 5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. : Relates to the shaft seal. Step 9 Single shaft seal: 1. Remove the complete shaft seal from stub shaft (7). 2.

  • Page 31: Assembly Of Pump/Single Shaft Seal

    5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. : Relates to the shaft seal. 5.3 Assembly of pump/single shaft seal Step 1 1. Remove spring (13). NOTE! Make sure that O-ring (15) has max. clearance from the sealing surface.
  • Page 32 5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. : Relates to the shaft seal. Step 5 1. Clean the sealing surfaces with contact cleaner before fitting back plate (25). 2.

  • Page 33: Assembly Of Pump/Double Mechanical Shaft Seal

    5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Lubricate the rubber seals before fitting them. : Relates to the shaft seal. 5.4 Assembly of pump/double mechanical shaft seal Step 1 1. Fit O-rings (15) in rotating seal rings (14). 2.
  • Page 34 5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Lubricate the rubber seals before fitting them. : Relates to the shaft seal. Step 6 1. To enable fitting of the back plate (25) with the shaft seal, remove connex pin (8) from stub shaft (7) (if fitted).
  • Page 35 5 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Lubricate the rubber seals before fitting them. : Relates to the shaft seal. Step 10 Fit safety guard (22) and screw (23) and tighten. If the pump is not supplied with flush connections, the holes in the adaptor must be covered by the guard.

  • Page 36: Adjustment Of Shaft

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Lubricate the rubber seals before fitting them. : Relates to the shaft seal. 5.5 Adjustment of shaft Step 1 1. Loosen screws (6). 2.
  • Page 37 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Lubricate the rubber seals before fitting them. : Relates to the shaft seal. Step 5 1. For double mechanical shaft seal: Fit drive ring (52) on stub shaft (7).

  • Page 38: Technical Data

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. 6.1 Technical data The LKHex UltraPure pump is a highly efficient and economical centrifugal pump, which meets the requirements of the pharmaceutical industries.

  • Page 39: Technical Information And Description Of Mechanical Shaft Seals

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. 6.2 Technical information and description of mechanical shaft seals General considerations regarding mechanical shaft seals The basic working principle of a mechanical seal is that the seal faces are cooled and lubricated by the process media or the flush media.

  • Page 40: Torque Specifications

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. 6.3 Torque specifications The table below specifies the tightening torques for the screws, bolts and nuts in this pump. Always use the following torques if no other values are stated.

  • Page 41: Noise Emission

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. 6.5 Noise emission Pump type Sound pressure level (dBA) LKHex UP-10 LKHex UP-15 LKHex UP-20 LKHex UP-25 LKHex UP-35 LKHex UP-40 LKHex UP-45 LKHex UP-50...

  • Page 42: Relubrication Intervals

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. 6.6 Relubrication intervals The table is for an internal bearing temperature of 100°C. An increase in temperature of 15°C (ambient or internal in bearings), will reduce the greasing interval and bearing lifetime by 50%.

  • Page 43: Parts List

    7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. 7.1 Drawing LKHex UltraPure -10, -20, -25, -35, -40, -45, -60, -70 3007-0112 US legs are different to the ones shown.

  • Page 44: Lkhex Ultrapure - Product Wetted Parts

    7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. 7.2 LKHex UltraPure - Product wetted parts 3001-0067 Product wetted steel parts Product wetted elastomer parts...
  • Page 45 7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. Parts list Pos. Denomination Washer Cap nut Washer Backplate compl ♦ Pumcasing O-ring Bolt Connections and drain...

  • Page 46: Lkhex Ultrapure - Motor Dependent Parts

    7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. 7.3 LKHex UltraPure - Motor dependent parts 3001-0067 Product wetted steel parts Product wetted elastomer parts...
  • Page 47 7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. Parts list Pos. Denomination Motor Shroud Screw Compression ring Compression ring Screw Washer Shaft incl.

  • Page 48: Lkhex Ultrapure - Shaft Seal

    7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. 7.4 LKHex UltraPure - Shaft seal 3001-0067 Product wetted steel parts Product wetted elastomer parts...
  • Page 49 7 Parts list The drawing shows the LKHex UltraPure, sanitary version. The items refer to the parts lists in the following sections 7.2 LKHex UltraPure - Product wetted parts. Parts list Pos. Denomination ♦ Single shaft seal  Double mechanical shaft seal Drive ring Stationary seal ring O-ring...
  • Page 50 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.

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