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Alfa Laval ALP 15-85, Manual, Page: 47 / 59

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Alfa Laval ALP 15-85 Manual Download Page 47

7

Installation

3.

If the pump does not deliver after
10–15 seconds of operation, abort initial
commissioning, establish the cause of
the fault and only then continue the
commissioning procedure. Follow the
instructions in the fault table, see

4.2

Troubleshooting on page 19

.

4.

Run the pump for a few minutes to allow the
pipe system to vent fully. The pipe system
is fully vented when there is a smooth
operating noise and a pressure gauge on
the pressure side of the pump shows no
more fluctuations.

7.6.4

Taking the pump out of
operation

!

WARN

ING

Risk of injury or poisoning through emitted
pumped liquid.

Wear protective clothing during all the work.

Collect the emitted pumped liquid safely and dispose
of it in an environmentally compatible manner.

Carry out the following measures during shutdowns:

Pump is

Measure

shut down for longer period

Depending on pumped liquid, see below..

drained

Close the pressure-side and suction-side shut-off
devices.

dismantled

Disconnect the motor from the power supply and secure
it against being switched back on.

stored

Observe measures for storing and preservation, see
page

51

.

Measures for operation interruption

Behavior of the pumped
liquid

Duration of the shut down
Short

Long

sediment solids

Rinse the pump.

Rinse the pump.

congealed/frozen

Heat or drain the pump.

Drain the pump.

no corrosive burden
congealed/frozen

Heat or drain the pump.

Drain the pump.

corrosive burden

Preserve the pump.

remains liquid

—

—

47

Summary of Contents for ALP 15-85

Page 1: ...Marine Diesel Equipment Oil Feed Pumps ALP 15 85 X02 7 35 1A Product No Printed Book No Jan 2020 9006009 02 V13 Component Description ...

Page 2: ...n Telephone 46 8 530 650 00 Telefax 46 8 530 310 40 Alfa Laval Tumba AB 01 2020 Original instruction This publication or any part there of may not be reproduced or transmitted by any process or means without prior written permission of Alfa Laval Tumba AB ...

Page 3: ... Fault Finding 19 4 1 Possible faults 19 4 2 Troubleshooting 19 5 Maintenance 23 5 1 Safety instructions on maintenance and repairs 23 5 2 Required maintenance 24 5 3 Mechanical seal 24 5 4 Ball bearing 24 5 5 Cleaning the leakage vent hole 25 5 6 Replacing the elastomer coupling 26 5 7 Replacing the mechanical seal and ball bearing 29 5 7 1 Dismantling 29 5 7 2 Assembly 31 6 Technical Data 33 6 1...

Page 4: ... Filling the pump 44 7 6 3 Checking the direction of rotation 46 7 6 4 Taking the pump out of operation 47 7 6 5 Recommissioning the pump 48 8 Transportation storage and disposal 49 8 1 Unpacking and checking the state of delivery 49 8 2 Lifting the pump pump unit 50 8 2 1 Pump 51 8 2 2 Pump unit 51 8 3 Storage 51 8 3 1 Preservation 52 8 3 2 Preserving the internal surfaces of the pump 52 8 3 3 Pr...

Page 5: ...ervice and maintenance Not following the instructions can result in serious accidents In order to make the information clear only foreseeable conditions have been considered No warnings are given therefore for situations arising from the unintended usage of the machine and its tools 5 ...

Page 6: ... ...

Page 7: ...ty with Machinery Directive 2006 42 EC and furthermore declares that if motorised the following applicable directives have been used Directive 2014 35 EU on low voltage EMC Directive 2014 30 EU The technical construction file for this machinery has been drawn up The signer of this declaration is authorized to compile the technical file Manager Product Center Fluid Handling Bjarne Søndergaard Title...

Page 8: ...1 EC Declaration of Conformity ...

Page 9: ...es an imminently hazardous situation which if not avoided will result in death or serious injury WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury NOTE NOTE indicates a potentially hazardous situation which if...

Page 10: ...2 Warning signs in text ...

Page 11: ...r The pump is specifically configured for the operating pressure stated in chapter 5 3 1 1 Safety information The following general safety instructions must be observed No liability is accepted for damage arising through non observance of the operating instructions Read the operating instructions carefully and observe them The operator owner is responsible for the observance of the operating instr...

Page 12: ... meshing of three rotating screws and the enclosing housing The radial support of the screws is effected by the sliding contact in the housing which requires lubrication by the pumped liquid Screw pumps are therefore not suitable for dry running and can only be used up to specific pressure and viscosity limits Due to the narrow tolerances pumping of suspended solids is not possible Axial support o...

Page 13: ...l overheat and be destroyed in a matter of minutes 3 2 2 Direction of Rotation Standard direction of rotation clockwise viewed from the drive marked on the housing by two arrows see 7 6 3 Checking the direction of rotation on page 46 Flow direction marked on the housing by two arrows see 7 6 3 Checking the direction of rotation on page 46 3 2 3 Pressure relief valve The integrated pressure relief ...

Page 14: ... seal 2 Screw plug 11 Pump 3 Idle screw 12 adapter housing 4 End cover 13 Motor 5 Sealing sleeve 14 adapter housing foot 6 Ball bearing 15 Motor side coupling half 7 Main screw 16 Coupling intermediate ring 8 Pump housing 17 Pump side coupling half 9 Leakage vent hole 14 ...

Page 15: ...3 Function Description X027101A Fig 1 Structure of ALP pump X027111A Fig 2 Structure of ALP pump with elastomer coupling and motor 15 ...

Page 16: ...58 L ring 661 Screw set 070 End cover 739 1 O ring 131 Pump housing 817 Ball bearing 165 1 Screw plug 866 Feather key 165 2 Screw plug 894 Hexagon nut 180 Pump bracket 914 1 Socket screw 222 Flat gasket 914 2 Socket screw 305 Valve body 914 3 Socket screw 457 Mechanical seal 914 4 Socket screw 471 Circlip Only for sizes 15 20 In case of wear of the screw set it is recommended to replace the pump O...

Page 17: ...on 070 914 1 165 1 222 131 165 2 305 501 859 866 661 457 739 1 043 817 056 471 472 056 8 X027151A Fig 1 ALP 15 85 914 2 001 525 894 526 180 914 4 529 914 3 052 039 X027161B Fig 2 Completion elastomer coupling ALP 15 85 17 ...

Page 18: ...3 Function Description ...

Page 19: ...s in the suction pipe and open them if necessary 2 Suction valve or pipe obstructed Check the suction valve and pipe for clear passage 3 Suction pipe or shaft seal leaks Check suction pipe or shaft seal for leaks Pay particular attention to leakage at valves and connection points If necessary replace parts Reinstall the pump at lower suctiion head level or Reduce pipe length or Increase pipe diame...

Page 20: ...ure 15 Pressure relief valve leaks Clean the pressure relief valve and reseat if necessary Check screw set and housing and replace the pump if necessary 16 Advanced wear of rotating pump components Replace the seal and check the pumped liquid for abrasive content 17 Advanced wear of sealing surfaces Support the weight of the pipe system 18 Pump distorted Loosen pipework connections and mount stres...

Page 21: ...one If necessary replace the pump 27 Differential pressure is too high and has overloaded the screws Reduce the differential pressure Dismantle the pump and clean it Smooth the superficial damage to the housing and the rotating parts with an oilstone If necessary replace the pump 28 Viscosity is too low and has overloaded the screws Increase the viscosity for example by reducing the operating temp...

Page 22: ...4 Fault Finding ...

Page 23: ...lothing during all the work Switch off the motor and secure it against being switched back on Before beginning the work let the pump the pump unit cool down to the ambient temperature and remove it from the pipe system Ensure that the pump is depressurized Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner Also observe the general drawings during all...

Page 24: ...ousing Replace the pump Tab 1 Check table for required maintenance 1 Check the pump visually and acoustically every four weeks 2 Check for signs of wear as listed in the table above and eliminate the cause 5 3 Mechanical seal Mechanical seals are subject to a natural wear that depends strongly on the respective conditions of use General statements about the durability can therefore not be given In...

Page 25: ...g damage due to insufficient drainage of shaft seal leakage X027171A Fig 1 Cleaning the leakage vent hole Check permeability of leakage vent hole regularly 1 Remove any drainage line that is connected 2 Check the permeability of the drainage line Observe whether a small amount of added liquid drains or Check visually or Insert an arbor made of a soft material wood plastic etc see Fig 1 3 Clean the...

Page 26: ...amage to equipment should the pump pump unit fall Lift large pumps pump units using the crane Do not stand under raised loads 1 Before dismantling close the suction and pressure connection of the pump with protective covers 2 Loosen the connecting screws 914 3 between the motor 529 and adapter housing 180 and lift the pump with adapter housing from the motor see Fig 2 3 Loosen the fixing screw on ...

Page 27: ...g levers Installing the coupling 1 Slide the pump side coupling half 052 1 onto the shaft until it stops Heating the coupling to 80 100 C facilitates mounting Tighten the fixing screw of the coupling half 2 Place the adapter housing 180 on the pump and tighten the connecting screws 914 2 see Fig 4 X027201A 3 Measure and write down the distance X between the face of the coupling and the connecting ...

Page 28: ...e value X c see table below 6 Insert the coupling intermediate ring 525 and tighten the fixation screw at the coupling half 052 2 7 Place the pump with the adapter housing on the motor 8 Turn the pump slightly until the teeth of the pump side coupling half 052 1 mesh correctly into the spaces of the coupling intermediate ring 525 9 Tighten the connecting screws 914 3 between the motor and adapter ...

Page 29: ...9 Open end wrench Extractor 1 Remove the circlip 472 screw plug 165 1 and feather key 866 see Fig 7 X027231A 2 Screw in the disassembly tool A by using the open end wrench B see Fig 8 The main screw will be pressed out of the pump housing Remove the main screw from the pump housing X027241A 3 Remove the circlip 471 and supporting ring 056 see Fig 9 X027251A 29 ...

Page 30: ...g 10 X027261A 5 Remove L ring 058 supporting ring 056 sealing sleeve 043 along with o ring 739 1 and stationary seal ring of the mechanical seal along with o ring see Fig 11 457 043 056 739 1 Fig 11 8 X027271A 6 Remove the remaining parts of the mechanical seal 457 from the main screw see Fig 11 30 ...

Page 31: ...X027613A 3 Press the stationary seal ring of the mechanical seal along with o ring manually into the sealing sleeve 043 see Fig 12 Take the position of the clearance for the adapter sleeve 859 into account X027281A 4 Slide the remaining parts of the mechanical seal 457 onto the main screw see Fig 13 457 Fig 13 X027561A 5 Slide the new o ring 739 1 onto the sealing sleeve 043 and slide the sealing ...

Page 32: ...lide the main screw with premounted sealing sleeve into the pump housing until the main screw engages into the idle screws see Fig 16 In doing so turn the main screw and take the position of the clearance for the adapter sleeve into account X027321A 8 Mount the screw plug 165 1 circlip 472 and feather key 866 see Fig 17 X027331A 32 ...

Page 33: ...z 2 900 at 60 Hz 3 500 6 2 Required Net Positive Suction Height NPSH values The following table lists the required NPSH values during operation with a low volatile liquid such as lubricating oil or hydraulic liquid When liquids have a readily volatile component content the required NPSH values increase notably when the pumped liquid contains water e g heavy fuel oil the values in the table have to...

Page 34: ... 5 4 0 6 2 0 6 2 0 2 6 3 0 37 2 0 37 2 0 2 9 3 4 152 2 0 2 4 2 7 152 2 3 2 5 3 3 4 1 ALP 20 380 2 2 2 4 3 2 3 8 ALP 75 380 2 7 3 0 4 4 5 0 6 2 0 6 2 0 2 8 3 4 37 2 0 37 2 0 3 1 3 8 152 2 0 2 3 2 6 152 2 4 2 6 3 8 4 6 ALP 30 380 2 2 2 4 3 1 3 7 ALP 85 380 2 8 3 1 4 6 5 8 6 2 0 2 3 37 2 0 2 1 2 6 152 2 0 2 8 3 5 ALP 40 380 2 5 2 7 4 0 4 8 6 3 Weights ALP weights with elastomer coupling Motor size Si...

Page 35: ...Pump unit mm LP LL LM LG L5 L5 1 L6 L7 L8 L9 H1 H2 B2 B3 S4 15 20 80 157 110 60 90 21 89 12 112 210 180 Ø11 90 157 118 60 90 19 99 12 112 210 180 Ø11 100 112 157 128 185 230 106 109 15 155 250 215 14x24 30 40 80 208 110 60 90 21 97 12 112 210 180 Ø11 90 208 118 60 90 19 107 12 112 210 180 Ø11 100 112 208 128 185 230 106 117 15 155 250 215 14x24 55 85 90 226 118 60 90 19 114 12 112 210 180 Ø11 100 ...

Page 36: ...6 Technical Data 6 4 1 Dimension drawing of ALP pump and pump unit X027341A 36 ...

Page 37: ...1 0 75 934 1 014 1 038 1 067 1 096 1 121 1 144 1 149 1 158 ALP 40 2 2 4 606 4 713 4 746 4 784 4 822 4 856 4 887 4 893 4 905 1 1 2 129 2 236 2 268 2 307 2 345 2 379 2 409 2 416 2 427 0 75 1 244 1 351 1 384 1 422 1 460 1 494 1 525 1 531 1 543 ALP 55 3 6 326 6 464 6 505 6 555 6 604 6 647 6 687 6 695 6 710 2 2 2 939 3 077 3 118 3 168 3 217 3 260 3 300 3 308 3 323 1 5 1 729 1 867 1 909 1 958 2 008 2 05...

Page 38: ... 2 5 668 5 775 5 807 5 846 5 884 5 918 5 948 5 955 5 966 1 1 2 659 2 767 2 799 2 838 2 876 2 910 2 940 2 947 2 958 0 75 1 598 1 705 1 738 1 776 1 814 1 848 1 879 1 885 1 896 ALP 55 3 7 777 7 915 7 957 8 006 8 056 8 099 8 138 8 146 8 161 2 2 3 665 3 803 3 844 3 893 3 943 3 986 4 026 4 033 4 048 1 5 2 213 2 351 2 393 2 442 2 491 2 535 2 574 2 582 2 597 ALP 75 3 10 050 10 212 10 261 10 318 10 376 10 ...

Page 39: ...Pos Designation Type 1 Model ALP 2 Size Corresponds to flow rate in l min at 1 450 min 1 3 Shaft seal B Mechanical seal of hard material D Magnetic coupling 4 Pressure stage A 6 bar overflow valve B 10 bar A Pump with free shaft end B With adaptor housing and coupling flange mounted C With adaptor housing coupling and foot foot mounted D B with motor 5 Completion E C with Motor 6 Frame size 080 09...

Page 40: ...6 Technical Data ...

Page 41: ... can be carried out easily 7 1 Installing the pump The pump must be installed to meet the following demands The pump must be mounted on a solid foundation and on a drip tray or in a cofferdam The pump can be operated vertically or horizontally However if vertically mounted the pump should not be mounted above the motor since pumped liquid could enter the motor should a leak occur The pump must be ...

Page 42: ...damage through impurities in the pipe system 1 During welding work attach protective covers in front of the connecting flanges 2 Ensure when welding that welding beads and abrasive dust cannot get into the pipe system and the pump 3 After the connecting work clean the pipe system thoroughly see 7 6 1 Cleaning the pipe system on page 44 42 ...

Page 43: ...ipe should be arranged so it forms a liquid trap together with the pump The liquid trap should secure that the pump is kept at least half filled with oil at stand still Shut off valves must be installed on both sides of the pump The suction line should be dimensioned for an oil flow speed between 0 5 and 1 2 m s and the pressure line for 1 to 3 m s The suction line must be equipped with a port nea...

Page 44: ...e followed when the pump is taken into operation after installation and whenever the pump casing has been emptied of oil for example when the pump has been dismantled WARNING Entrapment hazard Do not start filling the pump unless the power is switched off 1 Remove the fan cover from the electric motor 2 Turn the pump shaft or the fan impeller of the motor This tests that the pump runs smoothly If ...

Page 45: ...deaeration plug 3 and fill the shaft seal compartment with oil Fit and tighten the plug X027514A 8 Fill the pump with oil while rotating the pump manually The pump is rotated by turning the motor fan in the direction indicated by the rotation arrow on the motor or connection flange There are arrows for inlet and outlet directions on the pump Do not mix them up with the rotation arrow 9 When the pu...

Page 46: ... 2 Arrow for direction of rotation CAUTION Dry running can damage pump equipment Ensure that the pump is filled properly Switch the pump on for a maximum of 1 second and then off again immediately CAUTION Dry running can damage pump equipment Ensure that the pump is filled properly If the pump does not deliver after 10 15 seconds abort commissioning 1 Ensure that the pump is filled In case of doub...

Page 47: ...othing during all the work Collect the emitted pumped liquid safely and dispose of it in an environmentally compatible manner Carry out the following measures during shutdowns Pump is Measure shut down for longer period Depending on pumped liquid see below drained Close the pressure side and suction side shut off devices dismantled Disconnect the motor from the power supply and secure it against b...

Page 48: ...osive burden Preserve the pump Measures depending on behavior of the pumped liquid Drain the pump via the pressure and suction line and vent screw 7 6 5 Recommissioning the pump Carry out all the steps as for the commissioning process see 7 6 Commissioning on page 44 48 ...

Page 49: ...d checking the state of delivery 1 Upon delivery unpack the pump pump unit and check for transport damage 2 Report any transport damage immediately to the manufacturer 3 Dispose of packing materials in accordance with the locally applicable regulations 49 ...

Page 50: ...ciently dimensioned hoisting equipment The used hoisting equipment conforms to the local regulations and health and safety regulations D ANGER Risk of injury and or damage to equipment should the pump pump unit fall Use intact and correctly dimensioned hoisting equipment suitable for the weight to be lifted 50 ...

Page 51: ... possible take other suitable measures to prevent the pump unit from tilting 2 Secure the slings against slipping for example with screwed in eye bolts 3 Attach the slings onto the crane hook and lift the pump unit 8 3 Storage During the test run the internal components of the pump are wetted with test oil which has a preservative effect The pipe connections are fitted with protective covers The e...

Page 52: ...resin free oil into the pressure connection until it reaches approx 2 cm under the pressure flange while slowly turning the main screw against the direction of rotation 3 Close the pressure connection of the pump with a blind flange After about 6 months storage check the oil level in the pump and top up if necessary 8 3 3 Preserving the external surfaces of the pump Aids Preservative e g Castrol R...

Page 53: ...pump Collect the emitted oil safely and dispose of it in an environmentally compatible manner 1 Clean the outside of the pump with solvents if necessary using a steam jet cleaning device 2 Remove the blind flange on the pressure side 3 Drain the pump collecting the preservative oil in a suitable vessel 4 Remove the blind flange on the suction side 5 To remove the residual oil rinse the pump with t...

Page 54: ...scharging pumped liquid and oil and dispose of it in accordance with the locally applicable regulations Neutralize any residues of the pumped liquid 1 Disassemble the pump 2 Clean residues of the pumped liquid from the individual parts 3 Separate sealing elements made of elastomers and ceramics SiC from the pump and dispose of them in the residual waste 4 Recycle metal parts 54 ...

Page 55: ...6 058 X027151B Image show available spare parts ALP 15 85 9 1 Spare part kits Pump size Kit type Part no O ring Kit 9007162 86 ALP 15 20 Overhaul Kit 9007162 81 O ring Kit 9007162 87 ALP 30 40 Overhaul Kit 9007162 83 O ring Kit 9007162 88 ALP 55 85 Overhaul Kit 9007162 85 55 ...

Page 56: ...1 471 Circlip 1 056 Supporting ring 1 056 Supporting ring 1 058 L ring 1 Disassembly tool 457 1 457 2 X027122B Only for sizes 15 20 B Overhaul kit 1 457 Mechanical seal 1 222 Flat gasket 1 817 Ball bearing 1 739 1 O ring 1 472 Circlip 1 471 Circlip 1 056 Supporting ring 1 056 Supporting ring 1 058 L ring 1 866 Feather key 1 Disassembly tool 222 457 739 1 817 056 471 472 058 056 866 X027516B Only f...

Page 57: ...075 0085 132 9029429 02 Cylindrical spring 501 Part no 9014370 01 ALP15 ALP20 6 bar 9014370 02 ALP15 ALP20 10 bar 9014370 03 ALP30 ALP85 6 bar 9014370 04 ALP30 ALP85 10 bar 501 X027151D Sealing sleeve 043 Part no ALP15 ALP20 9029771 01 ALP30 ALP40 9029771 02 ALP55 ALP75 ALP85 9029771 03 X027151E Drain pipe 155 Part Qty Dimensions Part Alfa Laval HHR1201 1 20x1 5x60 mm 0 2 mm 902447901 57 ...

Page 58: ...28 01 Flange gasket D 25mm 1764629 01 28 28 25 62 X027151F ALP 0015 and ALP 0020 2x 1764629 01 D 25mm 40 28 40 62 25 90 X027151g ALP 0030 and ALP 0040 1x 1764629 01 D 25mm 1x 1764628 01 D 40mm 40 40 40 90 X027151h ALP 0050 ALP 0075 ALP 0085 2x 1764628 01 D 40mm 58 ...

Page 59: ... 8 13 M4 2 9 4 1 2 3 3 2 G1 4 30 M5 6 0 8 0 4 8 6 0 3 9 3 5 4 7 G3 8 60 M6 9 5 14 7 6 10 3 6 9 6 8 G1 2 80 M8 23 1 34 18 4 25 17 16 22 G3 4 120 M10 46 68 36 8 47 33 32 43 G1 200 M12 80 117 64 84 56 56 75 G1 1 4 400 M14 127 186 101 133 89 G1 1 2 450 M16 194 285 155 204 136 135 180 M18 280 390 224 284 191 M20 392 558 313 399 267 280 370 M24 675 960 540 687 460 455 605 reduced tightening torque when ...

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