Machine Manual HP Pump - Type P3: Issue No. 2 September 2005

Machine Manual Issue No.
2
HP Pump – Type P3 September 2005
1
Machine Manual Issue No. 2
Contents
1 INTRODUCTION............................................................................................................ 6
1.1 CONVENTIONS ........................................................................................................................ 7
1.2 SAFE OPERATION ................................................................................................................... 7
1.3 MANUAL CONTENTS................................................................................................................ 8
1.4 MANUAL USER GROUPS.......................................................................................................... 9
1.5 COPYRIGHT © ........................................................................................................................ 9
1.6 MANUFACTURER................................................................................................................... 10
1.7 PUMP IDENTIFICATION / CE-MARKING .................................................................................... 10
1.8 MACHINE DESIGNED USAGE .................................................................................................. 11
1.9 MACHINE CONFIGURATIONS .................................................................................................. 12
1.9.1 Designation Format........................................................................................................ 12
2 SAFETY ....................................................................................................................... 14
2.1 INTRODUCTION ..................................................................................................................... 14
2.2 EMERGENCY STOP ............................................................................................................... 14
2.3 GENERAL SAFETY PROCEDURES ........................................................................................... 14
3 TRANSPORTATION & STORAGE .............................................................................. 16
3.1 PACKAGING .......................................................................................................................... 16
3.2 TRANSPORTATION ................................................................................................................ 16
3.3 LIFTING EQUIPMENT ............................................................................................................. 17
3.3.1 Lifting by Hoist ............................................................................................................... 17
3.3.2 Forklift Truck .................................................................................................................. 17
3.3.3 Truck (lorry).................................................................................................................... 17
3.3.4 Caterpillar Tracks........................................................................................................... 17
3.4 CONDITIONS OF STORAGE .................................................................................................... 17
3.5 UNPACKING .......................................................................................................................... 17
4 MACHINE DESCRIPTION ........................................................................................... 19
4.1 SYSTEM DESCRIPTION .......................................................................................................... 19
4.2 GENERAL PUMP DESCRIPTION .............................................................................................. 21
4.3 PRODUCT SYSTEM DESCRIPTION .......................................................................................... 22
4.4 PUMPING COMPONENTS ....................................................................................................... 23
4.4.1 Pump Safety Valve ........................................................................................................ 23
4.5 PUMP DRIVE SYSTEM ........................................................................................................... 24
4.5.1 Pump Lubrication ........................................................................................................... 25
4.6 NITROGEN DOSING SYSTEM .................................................................................................. 26
4.6.1 Nitrogen Supply ............................................................................................................. 26
4.6.2 Nitrogen Control............................................................................................................. 26
4.6.3 Nitrogen Injection ........................................................................................................... 27
4.6.4 Aseptic Flushing Systems.............................................................................................. 27
5 INSTALLATION & COMMISSIONING ......................................................................... 29
5.1 PUMP ASSEMBLY & POSITIONING .......................................................................................... 29
5.1.1 Product Inlet................................................................................................................... 29
5.1.2 Product Outlet ................................................................................................................ 29
5.2 SERVICE CONNECTIONS........................................................................................................ 30
5.2.1 Power Supply................................................................................................................. 30
5.2.2 Safety Valve................................................................................................................... 30
5.2.3 Nitrogen Dosing Systems .............................................................................................. 30
5.2.4 Aseptic Flushing Systems.............................................................................................. 30
5.3 ELECTRICAL COMPONENTS ................................................................................................... 30
2
5.4 DIRECTION OF ROTATION ...................................................................................................... 31

5.5 LUBRICATION CHECK ............................................................................................................ 31
5.6 INITIAL CLEANING ................................................................................................................. 31
5.7 SETTINGS............................................................................................................................. 32
5.7.1 Safety Valve................................................................................................................... 32
5.7.2 Inlet & Outlet Valve ........................................................................................................ 32
5.7.3 Pump Speed .................................................................................................................. 32
5.7.4 Nitrogen Flowmeter........................................................................................................ 32
5.7.5 Nitrogen Electronic Controller........................................................................................ 32
5.8 INITIAL START UP ................................................................................................................. 33
6 OPERATING PROCEDURES...................................................................................... 35
6.1 START-UP PROCEDURE ........................................................................................................ 35
6.2 PLANT OPERATION ............................................................................................................... 36
6.2.1 Filtration ......................................................................................................................... 36
6.2.2 Product Inlet Temperature ............................................................................................. 36
6.2.3 Product Inlet Pressure ................................................................................................... 36
6.2.4 Product Outlet Pressure................................................................................................. 36
6.2.5 Product Throughput ....................................................................................................... 37
6.2.6 Product Leakage............................................................................................................ 37
6.2.7 Pump Speed Setting ...................................................................................................... 37
6.3 SHUT-DOWN PROCEDURES ................................................................................................... 38
6.3.1 Temporary Stoppages ................................................................................................... 38
6.3.2 Short Term Stoppages................................................................................................... 38
6.3.3 Stopping after Production .............................................................................................. 38
6.4 CLEANING ............................................................................................................................ 39
6.5 MANUAL CLEANING ............................................................................................................... 40
6.5.1 CIP Plant........................................................................................................................ 41
6.5.2 Detergents ..................................................................................................................... 42
6.5.3 Alkaline Cleaning ........................................................................................................... 42
6.5.4 Acid Cleaning................................................................................................................. 42
6.5.5 Chemical Disinfection .................................................................................................... 43
6.5.6 Intermediate and Final Rinse......................................................................................... 43
6.5.7 CIP Sequenses .............................................................................................................. 44
7 MAINTENANCE PROCEDURES................................................................................. 46
7.1 DISMANTLING SEQUENCES .................................................................................................... 46
7.2 PRELIMINARY PRECAUTIONS ................................................................................................. 47
7.2.1 CIP for Maintenance ...................................................................................................... 47
7.2.2 Isolating Electrical Power............................................................................................... 47
7.3 PUMP MOTOR/GEARBOX....................................................................................................... 48
7.3.1 Removing Motor/Gearbox Unit ...................................................................................... 48
7.3.2 Refitting Motor/Gearbox Unit ......................................................................................... 49
7.4 VALVE BLOCK....................................................................................................................... 50
7.4.1 Inlet Filter ....................................................................................................................... 50
7.4.2 Withdrawing the Valve Block ......................................................................................... 51
7.4.3 Refitting the Valve Block................................................................................................ 52
7.5 VALVE BLOCK ASSEMBLY ...................................................................................................... 53
7.5.1 Inlet & Outlet Valves ...................................................................................................... 53
7.5.2 Safety Valves ................................................................................................................. 53
7.6 PLUNGER SEALS .................................................................................................................. 54
7.6.1 Removing Plunger Seals ............................................................................................... 54
7.6.2 Refitting Plunger Seals .................................................................................................. 55
7.7 PLUNGERS ........................................................................................................................... 56
7.8 CONNECTING RODS .............................................................................................................. 58
7.8.1 Removing Connecting Rods .......................................................................................... 58
7.8.2 Refitting Connecting Rods ............................................................................................. 59
3
7.8.3 Ball Joint Bush Adjustment ............................................................................................ 60

7.9 CROSSHEAD ASSEMBLY ........................................................................................................ 61
7.10 CRANKSHAFT ....................................................................................................................... 62
7.10.1 Removing Crankshaft & Bearings ............................................................................. 62
7.10.2 Crankshaft Inspection................................................................................................ 63
7.10.3 Refitting Crankshaft & Bearings ................................................................................ 64
7.11 LUBRICATION ........................................................................................................................ 65
7.11.1 Pump Lubrication....................................................................................................... 65
7.11.2 Oil Leakage ............................................................................................................... 66
7.11.3 Motor/Gearbox Lubrication ........................................................................................ 66
7.12 ORDERING SPARE PARTS ..................................................................................................... 67
8 DISMANTLING & DE-COMMISSIONING .................................................................... 69
8.1 DE-COMMISSIONING ............................................................................................................. 69
8.2 RE-USE ................................................................................................................................ 69
8.3 DISPOSAL ............................................................................................................................ 69
4
Section 1
Introduction
5
1 INTRODUCTION
This document contains information on the SAFE, CORRECT, and EFFECTIVE use of the
P3 range of HP (High Pressure) Pumps. It is intended for the Owner, Operators,
Maintenance and Service Personnel. It also contains information for the Transport
Company responsible for shipment of the pump from the manufacturers to its installation
location. These instructions should always be available for the users of the pump.
This manual applies to the P3-55/80 and the P3-68/100 pumps. The illustrations are
generally based on the 55/80 pump and there are only minor design differences between
these two sizes. Where there are differences between these types, the text will clearly state
which machine it applies to as follows:
This procedure is only applicable to (TYPE OF) pump
This manual has been prepared using Microsoft Word 2000 and is available as:
• A4 paper hard copy
• Electronic format (Adobe Acrobat pdf file)
Figure 1 - P3 High Pressure Pump
6
1.1 Conventions
Throughout the manual supplementary comments may be inserted as follows:
Warning
Information to prevent a danger to yourself or other people.
Caution
Information to prevent damage to equipment.
Note - Supplementary information.
1.2 Safe Operation
This document MUST BE READ CAREFULLY before using the pump to ensure optimal and
safe operation is obtained. Only skilled qualified personnel must carry out its
recommendations and instructions with respect to:
• Transportation
• Installation
• Operation
• Maintenance
• Service
Any national rules and regulations concerning safety or environmental protection should
supplement and may supersede this document.
Caution
Only original replacement parts must be used for the pump. The use of any other parts will
void the Manufacturer’s liability.
If there are any queries regarding the contents of this document please contact the
manufacturer.
7
1.3 Manual Contents
Section Contents
1 INTRODUCTION
2 SAFETY
3 TRANSPORTATION & STORAGE
4 MACHINE DESCRIPTION
5 INSTALLATION & COMMISSIONING
6 OPERATING PROCEDURES
7 MAINTENANCE PROCEDURES
8 DISMANTLING & DE-COMMISSIONING
SUPPLEMENTARY DOCUMENTATION
8
1.4 Manual User Groups
The important sections of this manual for various user groups are indicated in the following
table:
Section Owner Operator Maintenance Service Shipping

Engineer Engineer Agent
INTRODUCTION
SAFETY
TRANSPORTATION &
STORAGE
MACHINE
DESCRIPTION
INSTALLATION &
COMMISSIONING
OPERATING
PROCEDURES
MAINTENANCE
PROCEDURES
DISMANTLING & DE-

COMMISSIONING
SUPPLEMENTARY
DOCUMENTATION
1.5 Copyright ©
The Company (Gerstenberg Schröder A/S, Copenhagen, Denmark) has the copyright of this
document.
Nothing from this publication must be duplicated, stored in any automated database or
published in any form or manner, either electronically, mechanically, by photocopying,
exposures, or any other method, without prior written consent of Gerstenberg Schröder A/S.
9
1.6 Manufacturer
The pump manufacturer is the company:
Gerstenberg Schröder A/S

22, Vibeholmsvej, DK-2605 Brøndby, Copenhagen, Denmark
Telephone +45 43 27 70 00
Fax +45 43 27 70 03
E-mail sales.dk@gs-as.com
Web Site http://www.gs-as.com
1.7 Pump Identification / CE-Marking
An identification plate is attached to the pump. The pump has been given a CE-
identification, thus declaring its conformity with the fundamental safety and health
requirements of the European Community. The Manufacturer's EC declaration of conformity
is included as the Supplementary Information.
Figure 2 - Typical Machine Nameplate
The pump safety valve has its set pressure stamped on it.
10
1.8 Machine Designed Usage
High pressure pumps are designed for

pumping various edible fats through
crystallisation and other process
equipment.
For a detailed description of the process

and pump construction refer to section 4.
This document contains the information required to ensure safe, correct and effective use of
the pump. It must always be available to the members of the user groups (see section 1.4
Manual User Groups) particularly Operators, Maintenance Engineers and Service
Engineers.
WARNING
High pressure pumps must only be used for processing the type of product that they were
specified for.
11
1.9 Machine Configurations
High pressure pumps are

designated by:
• Number of cylinders (3)
• Cylinder diameter in mm (D)
• Piston stroke in mm (S)
Figure 3 - Pump Designations
1.9.1 Designation Format
P - (Number of cylinders) - (Cylinder diameter in mm) / (Piston stroke in mm)
Examples:
• P-3-55/80
• P-3-68/100
12
Section 2
Safety
13
2 SAFETY
2.1 Introduction
High pressure pumps are designed and manufactured in compliance with the Machine
Directive 89/392/EEC issued by the European Community. The manufacturer’s EC
declaration of conformity is contained in the Supplementary Documentation. Pumps are
supplied with a CE marking which ensures that they comply with the fundamental safety and
health requirements of the European Community. Pumps will also have a recognised
pressure vessel certification (such as BS (UK), PED (Europe) or ASME (North America).
WARNING
Although the pumps have been designed and manufactured to conform to current
regulations and safety rules they can pose a risk if handled and operated incorrectly. Always
exercise great care when handling and operating the pump, it must only be used within the
limits defined in section 1.8 Machine Designed Usage. Before commencing work with the
machine, suitably qualified operators and servicing staff must have studied this manual.
2.2 Emergency Stop
It is a mandatory requirement that an emergency stop system is fitted and properly

maintained. It must be used immediately in the event of any dangerous situation to protect
personnel (and also to prevent damage to the machines). All personnel working in the
vicinity of machines must be aware of the exact location and operation of the emergency
stops.
2.3 General Safety Procedures
Although the pumps conform to the fundamental health and safety standards of the
European Community, dangerous situations can still occur. Personnel must be aware of
these potentially dangerous situations, with special emphasis on the avoidance of clothes,
hair or limbs becoming entrapped. The following minimum safety procedures must be
applied:
• Never switch on power to the machines when personnel are working within a danger
zone.
• Never start the machines if personnel are in contact with any component that could be
dangerous.
• When carrying out maintenance or servicing of the machines ALWAYS isolates the main
power supply.
• Maintenance or servicing should ALWAYS be carried out by at least two people.
14
Section 3
Transportation & Storage
15
3 TRANSPORTATION & STORAGE

3.1 Packaging
Before delivery, pumps are packed to suit the type of transportation to their destination. Two
typical forms of packing are:
• Light packing, with plastic covering, for transportation by truck or air.

• Seaworthy packing for transportation by ship.
Maintenance tools are normally included in the packages.
Each package is provided with common shipping marks with dimension and weight
information. Heavy packages are marked to indicate the centres of gravity. Seaworthy
packages are marked to indicate hook-up points for lifting straps. All packages can be
handled by forklift truck or crane. A packing list for each one is provided. Other types of
packaging may be agreed between the client and the manufacturer.
Shipping volumes and weight for the various pump sizes are provided in the Supplementary
Documentation - Shipping Data.
3.2 Transportation
WARNING
Pumps must be handled with extreme care. Lifting gear and forklift trucks for handling them
must have sufficient capacity appropriate to lift the weights indicated in the Supplementary
Documentation - Shipping Data.
Pumps can be moved by the following methods:

• lifted by hoist
• forklift truck
• truck (lorry)
• caterpillar tracks
16
3.3 Lifting Equipment
3.3.1 Lifting by Hoist
Adjustable-length straps must be used to prevent inclination of the pumps when they are
lifted.
3.3.2 Forklift Truck
Pumps can be moved by forklift trucks when positioned on a strong pallet.
3.3.3 Truck (lorry)
Pumps must be properly secured to trucks to ensure they cannot tip or slide.
3.3.4 Caterpillar Tracks

Low caterpillars tracks or low trolleys designed for heavy machine transportation can be
used for moving pumps short distances inside a factory.
3.4 Conditions of Storage
On arrival at their destination pumps should be kept in their original packing until installation.
If the installation is due within a few days after arrival the packages only need a
supplementary cover of plastic sheet, or be stored under cover in dry, dust free conditions.
Storage temperatures of between –30oC and +50oC are acceptable.
Machines must be preserved for storage of longer duration. Supplementary storage

instructions should be requested from GS if the storage period is likely to exceed 6 months.
3.5 Unpacking
Unpacking should only take place at the final place of installation.
17
Section 4
Machine Description
18
4 MACHINE DESCRIPTION
4.1 System Description
High pressure pumps form part of a fat crystallizing process system. This description is for
a typical system with various options, including intermediate crystallizers, pin rotor machines
and resting tubes.
1 The product – an oil emulsion - is prepared and supplied to the buffer tanks.
2 The emulsion is pumped out of the tanks through filters.
3 A plate heat exchanger is used to pasteurize the emulsion and to maintain a constant
temperature approximately 5oC above the melting point of the emulsion.
4 A high pressure pump forces the emulsion at a constant rate through the Perfector
chilling tubes and through other process equipment to the packing or filling machine(s).
High pressure is required because the emulsion becomes more viscous during the
crystallizing process.
5 In the Perfector tube the product is chilled and the crystallization starts. The product
may pass through several tubes of the Perfector.
Figure 4 - Crystallising Process System
Description continued on the next page
19
System Description (Continued)
6 Intermediate crystallizers may be used to texture the product between the chilling tubes.
7 The product may be passed through a pin rotor machine for further texture and
temperature stabilizing prior to further chilling or filling/packing.
8 The product may pass through a resting tube allowing it to settle prior to filling/packing.
9 Filling or packing machine.
Wrapable products are often extruded, cut into slabs or blocks and then wrapped.
Softer products are poured into containers.
10 Plate heat exchanger used for remelt of product diverted to the buffer tanks during plant
start-up or stop of filling/packing machine. A separate tank may be used for remelted
product.
20
4.2 General Pump Description
1 P series high pressure pumps have reciprocating plungers in 3 cylinders.

2 The plungers are driven from a rotating crankshaft. The cranks are spaced around the
crankshaft at 120 degrees. This configuration enables smooth operation of the pump,
with minimum vibration and pressure fluctuation.
3 A variable speed electric motor and gearbox drives the crankshaft.
4 Warm emulsion (typically about 40oC) from a heat exchanger enters the pump through
an inlet suction filter.
5 As each plunger moves in it sucks product up through a spring-loaded non-return valve
into the cylinder.
6 As each plunger moves out it forces product up through a spring-loaded non-return
valve into pump outlet manifold.
An aseptic flushing system may be fitted to collect product leakage from the plunger seals -
see section 4.6.4. A nitrogen dosing system may be fitted for shortening products - see
section 4.6.
Figure 5 - General Machine Description
21
4.3 Product System Description
The illustration shows the product flow through the pump
Figure 6 - Product Flow
22
4.4 Pumping Components
1 An inlet filter is fitted into the

suction manifold. The pump must
not be run without this filter fitted.
2 Spring-loaded inlet suction valves
connect each cylinder to the inlet
manifold. The suction valve springs
are much weaker than the
discharge valve springs and are not
interchangeable.
3 Plungers, driven from the
crankshaft, reciprocate in the valve
block.
4 Seals are fitted around each
plunger to provide a product seal.
5 Nitrogen injection may be fitted for
shortening products - see section
4.6.3.
6 Spring-loaded discharge valves
connect each cylinder to the
discharge manifold. The discharge
valve springs are much stronger
than the inlet valve springs and are
not interchangeable. Figure 7 - Pumping Components
Some degree of product leakage is inevitable so flushing systems may be fitted to remove
product from the plunger housings - see section 4.6.4.
The valve block can be withdrawn from the pump body to provide easy access for
maintenance.
4.4.1 Pump Safety Valve
The pump safety valve will open when product discharge pressure approaches the allowed
maximum pressure of the pump. The safety valve pressure is pre-set and sealed at the
manufacturers and it must not be adjusted without approval from G&A.
Safety valves can by supplied with the facility for remote controlled seat lift-off for cleaning
purposes.
WARNING
HP pumps must not be operated unless the safety valve is functioning correctly at the
required pressure. The safety valve pressure is pre-set and sealed at the manufacturers
and it must not be adjusted without approval from GS. If there is any doubt about safety
valve settings seek advice from GS.
23
4.5 Pump Drive System
1 The drive motor is fitted with a

frequency inverter to provide a
variable speed facility for the pump.
A separate fan motor cools the motor.
A thermo-sensor is fitted to stop the
motor if it overheats.
2 The motor drives via a helical bevel
gear
3 An inductive sensor may be fitted on
the coupling housing of the gearbox.
This senses a number of pins around
the rotating coupling. It can be used
to measure the product throughput to
signal the packing machine or in
connection with central factory
automated surveillance systems.
4 Pins on the drive motor gearbox
coupling engage in bronze bushes in
the crankshaft coupling to drive the
crankshaft.
5 The crankshaft is supported in 4
bearings:
Ball bearings on the P-3 - D/80 pump.
Roller bearings on the P-3 - 68/100 Figure 8 - Pump Drive System
pump.
6 A split connecting rod is fitted around each crank.

7 A ball-jointed rod drives each sliding crosshead.
8 The pump plungers are attached to the crossheads. They can be removed without
dismantling any other part of the drive system.
24
4.5.1 Pump Lubrication
1 The crankshaft rotates partly immersed in the oil sump.

2 This provides splash lubrication to the crankshaft bearings and the crossheads on the
connecting rods.
3 A flat disc at the non-drive end of the crankshaft throws oil up into an oil channel.
4 Oil flows down the channel and over the top of the crosshead housing.
5 Holes in the crosshead housing provide lubrication to the crossheads and connecting
rod ball joints.
Caution
The direction of rotation of the crankshaft (indicated by an arrow on the end casing) is
particularly important, as crosshead lubrication will only be effective in one direction.
Serious damage will result from any lubrication failure.
6 Remove the screw in the stainless steel top cover to ensure that the upper part of the oil
disk is moving towards the valve block.
7 Magnetic discs are screwed into the pump sump to retain any metal fragments.
Figure 9 - Pump Lubrication
25
4.6 Nitrogen Dosing System
Nitrogen systems are normally capable of dosing a maximum nitrogen volume of 15% into
the product. Various options are available to suit differing requirements.
4.6.1 Nitrogen Supply
1 Nitrogen is supplied from gas

bottles or a nitrogen
generator.
2 A regulator is fitted onto the
gas bottles.
3 Reduced pressure nitrogen is
supplied to a flow controller or
a flow meter.
Figure 10 - Nitrogen Supply
4.6.2 Nitrogen Control
A constant volume of nitrogen

flow is required independent of
pressure changes, this may be
via:
1 Mechanical flowmeter.
2 Flow controller.
OR
3 Electronic controller
4 The controller may be
connected to a readout unit or
PLC.
Figure 11 - Nitrogen Control
26
4.6.3 Nitrogen Injection
Nitrogen is piped from the controller

via
1 ....a stop valve and non-return
valve.
2 Nitrogen may enter each of the
plunger housings.
OR
3 Be injected directly into the
pump discharge manifold.
Figure 12 - Nitrogen Injection
4.6.4 Aseptic Flushing Systems
1 An aseptic flushing system may

be fitted to avoid product leakage
from the plunger seals collecting
under the pump. The seals are
flushed with liquid edible oil.
2 All pumps have a double seal
fitted inside the plunger
intermediate sleeve.
3 An additional seal is fitted in a 2-
piece split intermediate sleeve for
flushing systems.
Figure 13 - Aseptic Flushing System
27
Section 5
Installation
& Commissioning
28
5 INSTALLATION & COMMISSIONING

High pressure pumps must be correctly transported, handled, positioned and assembled.
This includes the installation of all services, product pipe work, electrical and any pneumatic
connections. Safe working conditions for all personnel involved must be provided with due
regard to Company and national rules at the place of installation.
5.1 Pump Assembly & Positioning
See also Unpacking - Section 3.5
Ensure that the pump is resting on all four legs; incorrect adjustment may cause it to vibrate.
Each leg is adjustable to compensate for sloping floors. Align the pump vertically upright.
Ensure that there is at least 0.6 m access all around the pump and there is sufficient space
to remove the inlet filter and motor/gearbox - refer to the Machine Dimensions Drawing.
5.1.1 Product Inlet

The product inlet pipe slopes slightly down towards the pump. The outlet from the tank or
pre-mixer should be at a sufficient height to ensure that the suction valves of the pump
always remain submerged. The inlet pipe should be as short as possible with the minimum
diameter of 3" (76.1mm x 1.6mm).
A centrifugal pump should always be used to feed the high pressure pump to give the
required product inlet pressure of between 2 bar and 3 bar.
5.1.2 Product Outlet

No valves or restrictions must be in the product outlet line before the pump safety valve.
The outlet pipe should be as short as possible with the minimum diameter of:
• 55/80 pump - 32 mm x 1.2 mm.

• 68/100 pump - 44.5mm x 2 mm.
High pumping pressures increase wear on the pump and on downstream process
equipment. It is good practice to ensure that ALL product pipes are the minimum length and
with the minimum of bends throughout the process system. All equipment and return pipes
(back to re-melt tank or pre-mixers) should also be efficiently heated. This will minimise the
internal friction and the pressure required to pump product through all of the process
equipment.
29
5.2 Service Connections

Ensure that all pipes connections and cables to the machine are properly mounted and
supported.
5.2.1 Power Supply

The supply cable must be sized according to the rated current of the machine.
Measure the voltages at the terminals before the machine is powered up.
5.2.2 Safety Valve

A safety valve MUST be fitted on the pump outlet manifold before any valves in the
discharge pipe. The safety valve vents to atmosphere and the vent outlet should point
down towards the pump to protect personnel in the event of it opening. The pump safety
valve has its set pressure stamped on it.
5.2.3 Nitrogen Dosing Systems

The hose connecting the nitrogen bottle to the flow meter must be internally clean and free
of dust and other particles.
Mechanical flow meters must be mounted absolutely vertically. The piping between the
mechanical flow controllers and the flow meters must be completely free from leaks.
Electronic flow controllers (which may be connected to a readout unit or a PLC) should be
installed according to the manufacturer's instructions.
5.2.4 Aseptic Flushing Systems

Aseptic flushing is carried out using liquid edible oil at 75oC. Flushing systems require a
flow rate of approximately 5 litres per hour.
Caution
STEAM MUST NOT BE USED FOR FLUSHING. Flushing liquids must only be circulated at
low pressures of between 1 to 1.5 bar. They must never exceed the pump inlet feed
pressure (normally 2-3 bar) to avoid any possibility of flushing liquid entering the product
through a leaking plunger seal.
5.3 Electrical Components
All electrical installation must be in accordance with national rules and regulations.
Check that all delivered electrical items correspond to the local voltage and frequency.
Refer to the Machine Electrical Diagrams.
30
5.4 Direction of Rotation
Caution
Check the direction of rotation of the crankshaft (indicated by an arrow on the top cover).
This is particularly important as the pump will appear to operate in either direction but the
lubrication system will only be effective in one direction. Serious damage will result from
any lubrication failure.
Rotation must always be such that the cranks throw oil up into the oil channel that provides
lubrication to the crossheads and connecting rods. Check the rotation by removing the
screw in the stainless steel top cover and ensuring that the upper part of the oil disk is
moving towards the valve block - refer to section 4.5.1.
5.5 Lubrication Check
Depending on the method of transportation the pump sump may already be filled with oil, or
it may be delivered empty. Check that pump sump is correctly filled with the approved oil -
see section 7.11.1
Check the pump motor gearbox is filled with oil - refer to the Gearbox Manufacturers'
Information.
5.6 Initial Cleaning
The pump (and any associated plant) should be thoroughly cleaned internally with a full CIP
sequence before putting into production. Refer to Section 6.4
31
5.7 Settings
5.7.1 Safety Valve
The pump safety valve has its set pressure stamped on it. The safety valve setting is sealed
and must not be adjusted without reference to GS.
5.7.2 Inlet & Outlet Valve

These are not adjustable and are designed to operate up to the maximum working pressure
of the pump of 120 bar.
5.7.3 Pump Speed

Pump speed is set to deliver the required amount of product to the process equipment.
5.7.4 Nitrogen Flowmeter

An inlet pressure of 7 bar (absolute) is
required for a mechanical flow meter,
which has been calibrated for this
pressure.
1 The nitrogen bottle regulator set

should be adjusted to give a pressure
of 6 bar (gauge) to the flow meter.
Providing that the flow meter inlet
pressure is 7 bar (absolute) the
volume of nitrogen can be read as
liters per hour directly from the flow
meter.
2 The flow rate can then be adjusted on
the adjusting valve on the flow meter.
The flow rate required will be
dependent on the pump speed. Figure 14 - Nitrogen Flowmeter
5.7.5 Nitrogen Electronic Controller

The nitrogen regulator set should be adjusted to give a pressure of 6 bar (gauge) to the flow
controller (7 bar absolute). The flow rate will then be automatically controlled to suit the
pump speed.
32
5.8 Initial Start Up
The first start up includes checks and tests to ensure correct and safe operation of the
pump.
Caution
Start-up must not be attempted until:
• all piping and electrical connections and a safety valve have been installed
• pipe connections have been pressure and leak tested.
Caution
Never start HP pumps unless there is product or water in the pump because these fluids act
as a lubricant for the plunger seals.
1 Ensure the oil in the pump sump is at the correct level.

2 Fully open all valves in the pump inlet and outlet pipes.
3 Start the pump.
4 Check for any product leaks - excessive leakage from the plunger seals may be an
indication of faulty seals.
5 Check the pump casing for any signs of overheating.
6 Adjust the motor speed to give the required throughput.
33
Section 6
Operating Procedures
34
6 OPERATING PROCEDURES
6.1 Start-Up Procedure
WARNING
Only qualified personnel must operate HP pumps.
Before you start the pump ENSURE THAT YOU KNOW HOW TO STOP IT! Find out
where the emergency stop buttons are.
Caution
To avoid serious damage HP pumps MUST NOT be operated:
• When cavitations (air within the product).
• Dry (with no product).
• Rotating in the wrong direction.
• With closed valves in the inlet and outlet pipes.
• With fluids containing strongly abrasive additives.
• Beyond their design capability.
• If solid product is present in the pump for any reason (which is not a situation that is
recommended) do NOT attempt to start the pump. Warm the pump inlet and outlet
manifolds and plunger housing with warm water until the product is soft.
1 Fully open all valves in the pump inlet and outlet pipes.
2 Start the pump.
3 Check for any product leaks - excessive leakage from the plunger seals may be an
indication of faulty seals.
4 Adjust the motor speed to give the required throughput.
35
6.2 Plant Operation
6.2.1 Filtration
The emulsion entering the HP pump must be well filtered to remove any impurities or hard
particles. To avoid damage to the plunger seals all salt crystals must be well dissolved so
that they can pass through the inlet filter. The inlet filter to the pump should be cleaned at
least once a day during production.
6.2.2 Product Inlet Temperature

The temperature of the liquid product entering the high-pressure pump should be 5oC above
the melting point of the product. It is recommended that this inlet temperature is kept
constant to maintain a consistent product quality.
6.2.3 Product Inlet Pressure

The product inlet pressure from the heat exchanger should be between 2 and 3 bar.
6.2.4 Product Outlet Pressure

This can be observed on the pressure gauge fitted to the outlet manifold. The pressure
depends on the resistance offered by the composition of the product and by process
equipment downstream of the pump - there is no "correct" pressure because the pump
speed is automatically adjusted to provide a constant throughput. However a sudden rise in
pressure is an indication of a process equipment problem downstream of the pump.
36
6.2.5 Product Throughput

Insufficient product capacity may be due to:
• blocked suction filter on the pump
• blocked filter upstream of the pump
• pump valves leaking
• pump valves with broken springs
• excessively worn plunger seals
Product delivery decreasing only when certain pressure is reached is normally due to the
safety valve opening too early. This may be caused by a safety valve spring becoming
weak over a period of time or the spring breaking.
Caution
The safety valve pressure setting must not be adjusted without reference to GS. The pump
must not be operated without a safety valve.
6.2.6 Product Leakage

A small amount of leakage may be expected from the pump plunger seals. Acceptable
leakage rates are:
• 55/80 pump - up to 150 millilitres per day

• Leakage above these levels indicates the plunger seals require renewal - see section
7.6.1
6.2.7 Pump Speed Setting
Refer to section 5.7.3
37
6.3 Shut-down Procedures
Ideally a CIP sequence should be carried out whenever a pump is stopped. However it is
recognised that this may not always be practical for some temporary and short-term
situations and the following procedures are recommended
Caution
It is NOT recommended to let product solidify in HP pumps when they are stopped.
6.3.1 Temporary Stoppages

A typical example of this would be a breakdown of the packing/filling equipment.
1 Product from the Perfector machine is normally diverted to re-melting equipment.

2 Refrigeration is taken off.
3 The high-pressure pump supplying the Perfector machine should be adjusted to
minimum capacity (slow speed) or stopped.
4 The Perfector rotors (and any pin rotor machines) should be left running.
6.3.2 Short Term Stoppages

A typical example of this would be overnight when CIP is not a practical option. The best
practice is wherever possible to leave the high pressure pump and downstream process
equipment filled with clean liquid oil until the next start-up.
1 Refrigeration is taken off the Perfector machines

2 Clean oil is pushed into the Perfector machine by the high-pressure pump, which is then
stopped.
3 The Perfector rotors can then be stopped.
6.3.3 Stopping after Production
1 Stop the high-pressure pump that is supplying product.

2 Stop the Perfector rotors.
3 Immediately carry out a CIP procedure - see section 6.4.
38
6.4 Cleaning
The HP pumps should be cleaned daily by one of the following methods:
• Manually cleaning by dismantling the valve block.

• CIP (Cleaning In Place) as an individual unit or part of a process system.
Cleaning should be of sufficient duration to ensure that the plunger cylinders and valve
blocks get thoroughly warm and until the water leaving the pump is clean and free from fat.
The inlet filter should be taken out daily and cleaned separately.
If debris becomes lodged between the safety valve and its seat, the valve may be flushed
through with water by unscrewing the plug on the valve body. Safety valves can by
supplied with the facility for remote controlled seat lift-off for cleaning purposes.
CIP cleaning is carried out by circulating a suitable detergent cleaning solution through the
pump, with the pump running. CIP can be carried out automatically or manually.
Caution
The temperature of any cleaning fluids must not exceed 90oC. When using any cleaning
agents it is important to observe the product specification and safety regulations specified in
the manufacturer’s product description together with any local regulations.
If the machine is not put into operation immediately after a CIP cleaning the pump should be
left ventilated to the atmosphere (through open inlet filter) to dry out the machine interior
and to accelerate the re-establishment of the protective chrome oxide layer on stainless
steel and hard chromium surfaces.
It is very essential for a good cleaning effect, that CIP fluid has a flow velocity of
approximately 2 m/s or higher in all cross sections of the fluid route and the CIP plant
should be designed according hereto.
Water for preparing CIP fluids and for final water flushing should be potable water quality in
accordance with EU and local regulations, but the concentration of chloride ion Cl- must
never exceed 300 mg/litre 1).
Cleansing solutions must be capable of passing through the same filters used for product.
Any small hard non-dissolved crystals may damage the valves and plunger shaft seals.
Powder detergents are not recommended.
1
According to DIN 11 483
Dairy installation - Cleaning and disinfection - Reference to the influence on stainless steel
39
6.5 Manual Cleaning
This method should be used only where the use of expensive solvents is necessary to
remove residues.
Caution
The pump valve block must be carefully dismantled to avoid damage to machined surfaces
of the pump components. Refer to section 7.4 for detailed dismantling instructions.
1 Rinse components in tepid water.

2 Immerse in a detergent or detergent-sterilizer solution at 45-50oC.
3 Brush detergent solution onto the components.
4 Thoroughly rinse in clean cold water then drain on a suitable surface protected from dust
and dirt until re-assembly.
Detergent resistant residues or scales should be soaked and brushed in a solution of

phosphoric acid 0.5% at 45oC. After the scale has been removed, re-immerse
components in the detergent solution at 45oC for two minutes and finally rinse in cold
water.
When components have been re-assembled circulate hot water at 80oC for approximately
15 minutes to effectively sterilize the machine.
40
6.5.1 CIP Plant

The HP pump can in this paragraph be apprehended as a Gerstenberg Schröder Scraped
Surface Heat Exchanger (GS SSHE).
Automatic CIP is carried out from a central CIP plant, see figure 15. This may also clean
other equipment in the factory but is programmed specifically for the GS SSHE.
Figure 15 - Central CIP Plant
Manual CIP can be carried out using a tank with dissolved detergents, see figure 16. The
tank is connected through a suitable CIP pump and strainer to the GS SSHE.
The CIP fluids in the tank can be heated by direct steam injection or by a built-in heating
coil.
Figure 16 - Central CIP Plant
41
6.5.2 Detergents
Caution
When using any cleaning agents it is important to observe the product specification and
safety regulations specified in the manufacturer’s product description together with any local
regulations.
Cleaning fluids must be capable of passing through the same filters used for the product.
Any small hard non-dissolved crystals will damage the hardened plating of chilling tubes,
bearing bushes and shaft seals.
If you are not going to use one of the following detergents please contact your local supplier
for detergents to choose an equivalent product. Detergents like caustic soda must not be
used because of a not recommended acid detergent is required to remove the base
residues in the pump. Detergents like HNO3 or H3PO4 must not be used because they do
not contain ingredients protecting the surfaces of the pump.
6.5.3 Alkaline Cleaning

For normal cleaning of pumps GS recommends using Alkaline cleaning solutions applied as
follows:
Detergent Concentration Temperature °C Duration

Ecolab:
0,7% - 1,5% 60 - 70 30 minutes
P3-mip CIP
JohnsonDiversey:
0,7% - 1% 60 - 70 30 minutes
Total VC2
6.5.4 Acid Cleaning

Gerstenberg Schröder does not normally recommend acid cleaning. However it may be
necessary occasionally to remove calcareous (lactic stone) scaling and in exceptional
circumstances the following acid cleaning agents can be used provided that the risk of
damage is fully understood.
Where plant residues (milk products for example) are likely to produce corrosive conditions
in contact with acid solutions, it is strongly recommended that alkaline solutions be
circulated BEFORE acid treatment.

Ecolab:
0,7% - 1,5% 50 - 60 10-15 minutes
P3-horolith CIP
JohnsonDiversey:
0,7% - 1-5% 50 - 60 10-15 minutes
Descale VA1
After initial acid cleaning the valve block should be opened and inspected. If the deposit has
not been removed repeat the acid cleaning but make a record of the total acid cleaning time
for future reference.
42
After acid cleaning always rinse with cold water.
The acid cleaning may be incorporated in an automatic CIP sequence from a central CIP
plant unit or carried out as a separate procedure.
6.5.5 Chemical Disinfection

If the pump has bacteriological contamination that normal CIP cleaning is unable to remove,
disinfection may be necessary. Pumps must be run continuously during this procedure.
Caution
If any disinfectants containing chloride compounds are used they must be drained out and
the plant thoroughly rinsed with cold water. This is to prevent spot corrosion, which may
shorten the life of certain components.

Ecolab:
0.3% - 0.5% cold 10 minutes
P3-oxonia active
JohnsonDiversey:
0.2% – 0.3% cold 10 minutes
Divosan Forte VT6
The chemical disinfection may be incorporated in an automatic CIP sequence from a central
CIP plant unit or carried out as a separate procedure.
NOTE, the above mentioned disinfectants must not be used for static disinfection over night
or weekend!
6.5.6 Intermediate and Final Rinse

The duration of intermediate rinse can be optimised by pH-value check. The final rinse with
potable water can be stopped by 5 to 10 minutes, if there are no characteristic chemical
ingredients in the water from the cleaning step before.
43
6.5.7 CIP Sequenses
Temperature Duration
Step o
C Minutes
Ambient
1 Rinse with water - to push the product out 5
temperature
2 Pre rinse with water 50 - 60 10
3 Alkaline cleaning 60 – 80 30
4 Intermediate rinse with water 60 – 80 5
5 Acid cleaning 1 50 - 60 30
Ambient
6 Intermediate rinse with water 5
temperature
7 Disinfection 2 cold 10
Ambient
8 Final rinse with potable water 10 – 15
temperature
1
This step is only applicable if acid cleaning is included – see section 6.5.5
2
This step is only applicable if chemical disinfection is included – see section 6.5.6
44
Section 7
Maintenance Procedures
45
7 MAINTENANCE PROCEDURES
WARNING
Only suitably qualified persons should carry out work on HP pumps. Only GS spare parts
must be fitted and the pump thoroughly tested on completion of work. No modification must
be made to the pump without the approval of GS. All safety devices such as pressure relief
valves and protective cover plates must be fitted and functioning correctly before attempting
to operate the pump
It is recommended that the inlet and outlet valves and the plunger seals be routinely
checked for wear. The frequency of inspections is dependent on the type of product and
operation conditions. Special maintenance tools for maintenance are supplied with the
pump. A list of tools is provided in the supplementary documentation.
Caution
Handle all internal components with care and keep them clean during maintenance.
7.1 Dismantling Sequences

The diagram shows the order of dismantling for the various components.
Figure 17 - Dismantling Sequences
46
7.2 Preliminary Precautions
WARNING
Before attempting maintenance procedures some or all of the following preliminary
procedures and safety precautions may be required:
• CIP the pump

• Isolate electrical power Abschalten der Stromversorgung
7.2.1 CIP for Maintenance

Before carrying out maintenance work on the product side of the pump carry out a full CIP
to remove all products and clean it. Ensure it is drained of all cleaning fluids - refer to
section 6.4.
1 Remove the filter to drain the pump inlet.

2 Disconnect the outlet manifold to drain the pump outlet
7.2.2 Isolating Electrical Power

Mechanical or electrical maintenance must only be carried out when the pump electrical
isolator switch is switched off and locked with a padlock. It is also recommended that any
emergency stop buttons are pushed in and power distribution to the pump is switched OFF
(on the distribution panel of the factory).
47
7.3 Pump Motor/Gearbox
It is recommended that if any maintenance work is required on the motor or gearbox that
they are removed as a unit and moved to a suitable workshop where clean dry conditions
exist. The motor/gearbox unit can be removed without removing any other components.
For maintenance information on the motor/gearbox refers to the Manufacturers' Information
supplied with the pump.
WARNING
Suitable lifting equipment (for example a hoist or a crane) must be available for removing
motor/gearbox units. The weight is shown in the Supplementary Information - Component
Weights. Ensure that the lifting equipment is capable of handling this weight.
7.3.1 Removing Motor/Gearbox Unit
1 Remove the motor/gearbox cover. Ensure

that electrical power is switched off and
isolated then disconnect the main power cable
at the motor terminal box.
2 If fitted, disconnect the cables from the
inductive sensor
3 Support the motor/gearbox unit with lifting
equipment by straps connected to eye-bolts
on the motor.
4 Remove the bolts fastening the gearbox to
the pump casing.
5 Move the motor/gearbox horizontally away so
that the coupling pins slide out of the bushes
on the crankshaft coupling then hoist the
motor away and put it down carefully on a
pallet.
6 The opportunity should be taken to examine
the bronze coupling bushes.
7 If required the oil seal can also be renewed.
Figure 18 - Remove
Motor/Gearbox
48
7.3.2 Refitting Motor/Gearbox Unit
1 Ensure the oil seal is correctly fitted

2 Ensure that coupling bushes are inserted into
the crankshaft coupling holes.
3 Support the motor with lifting equipment by
straps connected to eye-bolts on the motor.
4 Move the motor/gearbox horizontally towards
the pump crankshaft ensuring that the coupling
pins mesh into the crankshaft coupling bushes.
5 Refit the bolts fastening the gearbox/motor to
the pump casing and tighten to the
recommended torque.
6 If fitted, reconnect the cable from the inductive
sensor
7 Reconnect main power cable at the motor
terminal box. Check the direction of rotation of
the motor (normally indicated by an arrow on
the motor or console). Refit the motor/gearbox
cover.
Figure 19 - Refit
Motor/Gearbox
49
7.4 Valve Block

7.4.1 Inlet Filter
The inlet filter should be removed and cleaned daily.
Caution
The pump must not be run without the inlet filter fitted.
Figure 20 - Inlet Filter
50
7.4.2 Withdrawing the Valve Block
The valve block may be moved back on its support rods to allow access to the plungers and
the valve block for maintenance or internal cleaning.
• If nitrogen injection or aseptic seal flushing are fitted first disconnect the supply pipes.
1 Disconnect or remove the inlet filter manifold.

2 Disconnect or remove the discharge manifold.
3 Unscrew off the 4 large nuts securing the valve block to the pump body.
4 Remove the connecting hooks on the intermediate housings.
5 Pull the valve block back on its support rods.
6 On the 2 outer rods spring-loaded locking pins are fitted on the sliding bushes. These
lock the bushes onto the support rods when the valve block is in its fully withdrawn
position.
Figure 21 - Withdrawing Valve Block
51
7.4.3 Refitting the Valve Block
1 Ensure the plungers and plunger seals are correctly fitted - see section 7.6.1
2 Push the valve block fully in on its support rods (the locking pins will automatically
disengage)
3 Tighten the 4 large nuts to the recommended torque.
4 Refit the connecting hooks on the intermediate housings.
5 Reconnect or refit the discharge manifold.
6 Reconnect or refit the inlet filter manifold.
• If nitrogen injection or aseptic seal flushing are fitted, reconnect the supply pipes.
Figure 22 - Refitting Valve block
52
7.5 Valve Block Assembly
Caution
7.5.1 Inlet & Outlet Valves
All valves and valve housings are identical, however:
• Inlet (suction) springs are weak.

• Outlet (pressure) springs are strong.
1 Unscrew the union nuts and remove top outlet

manifold and inlet filter body.
2 Unscrew the valve bodies
3 Remove springs and valves.
Worn valves should be replaced with new valves. Ensure

that the correct springs are fitted to the inlet and outlet
valves.
Figure 23 - Inlet &

Outlet Valves
7.5.2 Safety Valves
The pump safety valve is pre-set at delivery to open when pressure approaches the
maximum permitted pressure of the pump. The safety valve pressure is pre-set and sealed
at the manufacturers and it must not be adjusted without approval from GS.
WARNING
HP pumps must not be operated unless the safety valve is functioning correctly at the
required pressure. If there is any doubt about safety valve settings seek advice from GS.
53
7.6 Plunger Seals
Caution
7.6.1 Removing Plunger Seals

Refer also to the Spare parts
drawing.
1 Withdraw the valve block -

see section 7.4.2
2 Pull off the long
intermediate sleeve
(connected to seal flushing
when fitted) from the
plunger housing.
3 Remove the short
intermediate sleeve
(connected to nitrogen
dosing when fitted) from
the valve block.
4 Remove all the seals and
distance pieces.
Figure 24 - Removing Plunger Seals
A 2-piece split intermediate sleeve is fitted for aseptic flushing systems to incorporate
an additional seal.
54
7.6.2 Refitting Plunger Seals
Refer also to the Spare parts

drawing.
1 Use the special tool to

clamp the ring and seal
onto the long intermediate
sleeve.
2 Fit the housings with
special tool attached over
the plunger and push it
fully up to the pump
casing.
3 Remove the special tool.
4 Refit the short intermediate
sleeve to the valve block
ensuring the bonded seal
is in position.
5 Fit the seals and distance
pieces into the short
intermediate housings.
6 Refit the valve block - see
section 7.4.3
Figure 25 - Fitting Plunger Seals
A 2-piece split intermediate sleeve is fitted for aseptic flushing systems to incorporate
an additional seal.
55
7.7 Plungers
This procedure is only applicable to P-3-D/80 pumps
Figure 26 - Type 55/80 Plunger
Refer also to the Spare parts drawing.
• Remove the plunger seals - see section 7.6.1
1 Unscrew the locking screw.

2 Remove the plungers by unscrewing them from the crossheads.
3 Remove the distance ring.
4 Inspect the plungers for wear.
Ensure that the distance ring is fitted before refitting the plungers. Tighten to the
recommended torque. Apply Loctite to the locking screw and tighten it up onto the plunger.
Fill the space above the locking screw with silicone filler.
• Refit the plunger seals - see section 7.6.2
56
7.7 Plungers
This procedure is only applicable to P-3-68/100 pumps
Figure 27 - Type 68/100 Plunger
Refer also to the Spare parts drawing.
• Remove the plunger seals - see section 7.6.1
1 Unscrew the two M10 screws.

2 Pull apart the coupling halves.
3 Remove the plungers.
4 Inspect the plungers for wear.
Caution
The plungers, crossheads and coupling halves are stamped 1-1, 2-2 and 3-3. Ensure that
each plunger and coupling is fitted to the corresponding crosshead.
Refit the plungers and fit the coupling halves over the crossheads and plungers.
Screw up the two M10 screws into each coupling and tighten to the recommended torque.
Ensure that the plunger is coupled firmly to the crosshead.
• Refit the plunger seals - see section 7.6.2
57
7.8 Connecting Rods
Caution
Connecting rods should only be dismantled where absolutely essential because they must
be precisely re-assembled.
7.8.1 Removing Connecting Rods
• Remove the plunger - see section 7.7

• Drain the crankcase of oil (Access the crank bearing bolts by removing the 5 magnetic
discs and the oil sight glass at the rear of the crankcase - see section 7.11).
1 Remove the top cover.

2 Remove the two bolts from the
split crosshead crank bearings.
3 Unscrew the ball joint bush
locking screws.
4 Unscrew the threaded flange
from inside the crosshead.
5 Pull back first split bush from
inside the crosshead (the second
split bush is pressed into the
crosshead).
6 The connecting rod may now be
removed with the first split bush
and threaded flange. Figure 28 - Connecting Rod Removal
Inspect the connecting rod bearings

and renew as necessary.
58
7.8.2 Refitting Connecting Rods
This procedure assumes that the original split bushes and ball joints are being refitted,
with their previous clearance.
Caution
The fit of the ball joint into the bushes in the crosshead slide is critical. The ball joint should
be carefully examined for any signs of wear - virtually no linear movement of the ball within
its bushes should be evident. If there is any doubt about the condition of the ball joint and
split bushes it is recommended that a complete replacement crosshead is fitted and any
worn or damaged components returned to GS for refurbishment.
Coat the ball joint with lubricating oil before refitting it.
1 Fit the connecting rod ball joint

(with the first split bush and
threaded flange attached) into
the crosshead.
2 Push the split bush on the
connecting rod over the ball joint
in the crosshead.
3 Screw up the threaded retaining
ring to push the split bush firmly
against the ball joint then
unscrew it slightly until the
locking screws align with the
drilled holes in the crosshead.
4 Apply Loctite to the ball joint Figure 29 - Connecting Rod Refitting
bush locking screws, insert and
tighten up the screws to the
recommended torque (see also
guidelines on ball joint bush
adjustment – section 7.8.3).
5 Fit both halves of the split crosshead crank bearings over the crankshaft. Apply Loctite
to the two bolts and tighten up to the recommended torque
6 Ensure that the 5 magnetic discs and the oil sight glass at the rear of the crankcase are
fitted then fill the crankcase to the correct level with oil - see section 7.11.
7 Refit the top cover.
59
7.8.3 Ball Joint Bush Adjustment
GS recommend that a complete replacement crosshead is fitted if the ball joint bushes
become worn. However should it be necessary to adjust the bush clearance on site the
following guidelines should be followed:
Components
1 Ball joint
2 Crosshead
3 Fixed bush
4 Adjustable bush
5 Screwed retaining ring
6 Retaining ring locking
Screws
7 Ball joint securing bolt
8 Crankshaft split bearing
The ball joint should have just

sufficient sliding clearance
between the bushes to allow it
to swivel.
Figure 30 - Ball Joint Bush Adjustment
9 Screw up the bush retaining ring to just grip the ball joint firmly and then UNSCREW the
retaining ring to provide a running clearance for the ball joint. The retaining ring should
be unscrewed by:
• 14 mm for P-3-55/80 pumps.
• 15 mm for P-3-60/100 pumps.
This distance is measured around the retaining ring on the pitch diameter by putting suitable
markings on the crosshead and retaining ring.
Check that the ball joint moves freely in the bushes. Mark the positions of the locking screw
holes on the retaining ring onto the crosshead and drill holes to accept the locking screws.
Apply Loctite to the locking screws, insert and tighten up the screws to the recommended
torque.
60
7.9 Crosshead Assembly
To remove a crosshead assembly:
• Remove the plunger - see section 7.7

• Remove the connecting rod- see
section 7.8
1 Undo the set screws and pull the

crankcase-cover flange and oil seal off
the crosshead shaft.
2 Pull the crosshead out of the crank
casing.
Coat the crossheads with lubricating oil

before refitting them, ensuring that oil
enters the ball joint bearings through the
lubrication holes. Ensure that the oil seal is
correctly refitted and that its securing bolts
are tightened to the recommended torque
setting.
Figure 31 - Crosshead Assembly
61
7.10 Crankshaft
7.10.1 Removing Crankshaft & Bearings
1 Remove the motor/gearbox

with oil seal - see section 7.3.1
2 Remove or disconnect the
connecting rods - see section
7.8.1
3 Remove the crankcase end
cover.
4 Remove the oil disc and oil
channel.
5 Remove the end stops from the
bearing housings.
6 Screw in an eye bolt into the
non-drive end of the crankshaft.
(see Figure 33) Pull out the
crankshaft with the bearings
still attached.
Some power assistance will

be required to pull the
crankshaft out - one method
is to lay the crankcase on its
end and use a power hoist.
7 Remove the circlips from either Figure 32 - Removing Crankshaft & Bearings
side of all of the bearings then
press the bearings off the
crankshaft.
62
7.10.2 Crankshaft Inspection
Figure 33 - Crankshaft & Bearings
• Remove the magnetic discs from the pump sump for inspection and cleaning Excessive
amounts of metallic particles on the disks is an indication of pump component wear.
1 Inspect the oil seals and renew as necessary.

2 Inspect the coupling bushes and renew as necessary.
3 Inspect the cranks for wear or damage.
4 Inspect the main bearings and renew as necessary.
5 Inspect the oil disc and oil channel for any damage or distortion.
6 Clean the end cover
Thoroughly clean out the oil sump before refitting components.
63
7.10.3 Refitting Crankshaft & Bearings
1 Pre-warm the bearings then fit

them onto the crankshaft.
2 Fit the circlips to either side the
bearings.
3 Fit the coupling bushes.
4 Apply Loctite to the securing
screws then refit the end stop
to the drive-end bearing
housing.
5 Align the coupling bushes with
the pins on the gearbox
coupling then, using a suitable
hoist, insert the crankshaft and
bearings into the crankcase.
screws then refit the end stop
to the drive-end bearing
housing.
screws then refit the oil disc
and oil channel.
8 Ensure that the crank can be
turned over by hand then refit
the crankcase end cover.
9 Refit or reconnect the
connecting rods - see section Figure 34 - Refitting Crankshaft & Bearings
7.8.2
10 Refit the motor/gearbox with oil
seal - see section 7.3.1
64
7.11 Lubrication
Recommended oils and greases are listed in the Supplementary Information -

Recommended Lubricants.
7.11.1 Pump Lubrication
Effective lubrication is essential to minimise wear on the pump components. The oil should
be changed initially after 3 months and then annually (or 2500 hours). The quantity of oil
required is approximately:
• P3-D/80 pump - 40 litres.

• P3-68/100 pump - 65 litres.
1 The sump has two screw

plugs at the top for oil
filling.
2 Magnetic discs are
screwed into the pump
sump to retain any metal
fragments. They should be
periodically inspected and
cleaned. Excessive
amounts of metallic
particles on the disks are
an indication of pump
component wear.
Figure 35 - Pump Lubrication
3 An oil sight glass is fitted on the back of the pump casing. Always check the oil level
before starting up. When the pump is not running the oil level should cover between ½
and 3/4 of the sight glass.
The discs and sight glass can be removed to gain access to the crankshaft bearing
bolts.
4 The sump has a screw plug at the bottom for draining oil (this plug also contains a
magnetic disc).
Lubrication for the crosshead is provided by an oil disc and channel - see section 4.5.1
65
7.11.2 Oil Leakage
A small amount of oil leakage may be expected from the HP pump. Acceptable leakage
rates are:

7.11.3 Motor/Gearbox Lubrication
Motors bearings are fitted with grease

nipples. Greasing should be carried out
as recommended by the motor
manufacturer.
1 The gearbox has an oil filler plug on

top of the housing.
2 An oil sight glass may be provided on
some types of gearbox.
3 The gearbox has a screw plug under
the housing for draining oil.
Oil filling of the gearbox should be carried

out as recommended by the
manufacturer.
Figure 36 - Gearbox Lubrication
66
7.12 Ordering Spare Parts
When ordering spare parts for pumps, GS require the following information to ensure that
the correct parts are dispatched:
1 Pump Type and Serial Number - this information is on the machine identification plate.
2 The Part Number and Quantity of Parts required. Part numbers can be identified in
the spare parts lists appendix to this manual.
3 A Purchase Order Number with customer name and delivery address
Gerstenberg Schröder A/S

Service & Spare Parts Departement
22 Vibeholmsvej
DK-2605 Brøndby
Copenhagen
Denmark
Telephone +45 43 27 70 00
Fax +45 43 27 70 03
E-mail sales.dk@gs-as.com
Website http://www.gs-as.com
67
Section 8
Dismantling &
De-Commissioning
68
8 DISMANTLING & DE-COMMISSIONING
8.1 De-Commissioning
This outlines the procedure for disconnecting and removing the pump.
During dismantling and removal due care and consideration should be taken,
dependant on whether the machine is being removed for destruction or re-installation.
1 Drain out all products and clean the product components of the pump.
2 Disconnect Product pipes at inlet and outlets of the pump.
3 Empty the pump of oil.
4 Clean the pump sump.
5 Disconnect and remove power supply cables.
8.2 Re-use
If the machine is to be re-installed at a different location refer to section Error! Reference

source not found..
8.3 Disposal
Although the pump is built with high quality materials with a minimal environmental pollution
potential, local legislation regarding environmental pollution should be observed, together
with the following procedures for components.
• Remove any plastic covers and send to a specialised certified disposal company.
• Remove lubricants from gearbox and pump sump for appropriate disposal.
• Remove motor, gearbox, electrical equipment and wiring and send to a specialised
certified disposal company.
69
Figures
Figure 1 - P3 High Pressure Pump ........................................................................................ 6

Figure 2 - Typical Machine Nameplate ................................................................................ 10
Figure 3 - Pump Designations.............................................................................................. 12
Figure 4 - Crystallising Process System .............................................................................. 19
Figure 5 - General Machine Description .............................................................................. 21
Figure 6 - Product Flow........................................................................................................ 22
Figure 7 - Pumping Components ......................................................................................... 23
Figure 8 - Pump Drive System ............................................................................................. 24
Figure 9 - Pump Lubrication................................................................................................. 25
Figure 10 - Nitrogen Supply ................................................................................................. 26
Figure 11 - Nitrogen Control................................................................................................. 26
Figure 12 - Nitrogen Injection............................................................................................... 27
Figure 13 - Aseptic Flushing System ................................................................................... 27
Figure 14 - Nitrogen Flowmeter ........................................................................................... 32
Figure 15 - Central CIP Plant ............................................................................................... 41
Figure 16 - Central CIP Plant ............................................................................................... 41
Figure 17 - Dismantling Sequences ..................................................................................... 46
Figure 18 - Remove Motor/Gearbox .................................................................................... 48
Figure 19 - Refit Motor/Gearbox .......................................................................................... 49
Figure 20 - Inlet Filter ........................................................................................................... 50
Figure 21 - Withdrawing Valve Block ................................................................................... 51
Figure 22 - Refitting Valve block .......................................................................................... 52
Figure 23 - Inlet & Outlet Valves .......................................................................................... 53
Figure 24 - Removing Plunger Seals ................................................................................... 54
Figure 25 - Fitting Plunger Seals.......................................................................................... 55
Figure 26 - Type 55/80 Plunger .......................................................................................... 56
Figure 27 - Type 68/100 Plunger ........................................................................................ 57
Figure 28 - Connecting Rod Removal.................................................................................. 58
Figure 29 - Connecting Rod Refitting................................................................................... 59
Figure 30 - Ball Joint Bush Adjustment ................................................................................ 60
Figure 31 - Crosshead Assembly......................................................................................... 61
Figure 32 - Removing Crankshaft & Bearings...................................................................... 62
Figure 33 - Crankshaft & Bearings....................................................................................... 63
Figure 34 - Refitting Crankshaft & Bearings......................................................................... 64
Figure 35 - Pump Lubrication............................................................................................... 65
Figure 36 - Gearbox Lubrication .......................................................................................... 66

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Machine Manual HP Pump - Type P3: Issue No. 2 September 2005

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Machine Manual Issue No.

5.4 DIRECTION OF ROTATION ...................................................................................................... 31

7.8.3 Ball Joint Bush Adjustment ............................................................................................ 60

Figure 1 - P3 High Pressure Pump

Throughout the manual supplementary comments may be inserted as follows:

 Note - Supplementary information.

1.2 Safe Operation

1.3 Manual Contents

3 TRANSPORTATION & STORAGE

5 INSTALLATION & COMMISSIONING

8 DISMANTLING & DE-COMMISSIONING

1.4 Manual User Groups

Section Owner Operator Maintenance Service Shipping

DISMANTLING & DE-

The pump manufacturer is the company:

Gerstenberg Schröder A/S

1.7 Pump Identification / CE-Marking

Figure 2 - Typical Machine Nameplate

1.8 Machine Designed Usage

High pressure pumps are designed for

For a detailed description of the process

1.9 Machine Configurations

High pressure pumps are

• Number of cylinders (3)

• Cylinder diameter in mm (D)

• Piston stroke in mm (S)

Figure 3 - Pump Designations

1.9.1 Designation Format

P - (Number of cylinders) - (Cylinder diameter in mm) / (Piston stroke in mm)

2.2 Emergency Stop

It is a mandatory requirement that an emergency stop system is fitted and properly

2.3 General Safety Procedures

Transportation & Storage

3 TRANSPORTATION & STORAGE

• Light packing, with plastic covering, for transportation by truck or air.

Maintenance tools are normally included in the packages.

Pumps can be moved by the following methods:

3.3 Lifting Equipment

3.3.1 Lifting by Hoist

3.3.2 Forklift Truck

Pumps can be moved by forklift trucks when positioned on a strong pallet.

3.3.3 Truck (lorry)

3.3.4 Caterpillar Tracks

3.4 Conditions of Storage

Machines must be preserved for storage of longer duration. Supplementary storage

Unpacking should only take place at the final place of installation.

Figure 4 - Crystallising Process System

Description continued on the next page

System Description (Continued)

4.2 General Pump Description

1 P series high pressure pumps have reciprocating plungers in 3 cylinders.

Figure 5 - General Machine Description

4.3 Product System Description

The illustration shows the product flow through the pump

Figure 6 - Product Flow

4.4 Pumping Components

1 An inlet filter is fitted into the

4.4.1 Pump Safety Valve

Note - Supplementary information.

Detergent resistant residues or scales should be soaked and brushed in a solution of