Behrens Pumpen
Final drawings and Manuals for Hyundai Samho Heavy Ind. HSHI 234
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str.7 - D-28307 Bremen Tel.: 49(0)421 49(0)421 4 86 81-0 - Fax: 49(0)421 49(0)421 4 86 81 11 - E-Mail:
[email protected]
Gauge, terminal box and flange position
Hull No.
Hyundai Samho Heavy Industries Co., Ltd. Ltd. 1700 Youngdang-Ri, Youngdang-Ri, Samho-Myun
HSHI 234
n g i s e D
l y a r n e e i v g i l n m r x e a e o l D f T b
n o e i g t i u a s o G p
61344
1
180°
270°
Loose
VRF 9/350
61345
1
0°
270°
Loose
Main cooling SW pump no.3
VRF 9/350
61346
1
0°
270°
Loose
6
FW generator ejector pump
VRF 3/350
61347
1
0°
270°
Loose
7
Bilge, Fire & GS pump no.1
VRF 7/350
61348
1
0°
0°
Loose
7
Bilge, Fire & GS pump no.2
VRF 7/350
61349
1
180°
180°
Loose
8
M/E JW cooling pump no.1
VRF 7/290 G
61350
1
180°
180°
C
8
M/E JW cooling pump no.2
VRF 7/290 G
61351
1
0°
0°
A
9
M/E air cooler chemical cleaning pump
SOH 222 W G
61352
5
90°
90°
A
10
Hot water circulating pump
UP 25-72/180
61353
1
0°
0°
Loose
11
Composite boiler feed water pump no.1
SFH 334 WW G
61354
5
90°
90°
A
11
Composite boiler feed water pump no.2
SFH 334 WW G
61355
5
90°
90°
A
15
Main LO pump no.1
VAL 302/2R
61356
2
0°
90°
Loose
15
Main LO pump no.2
VAL 302/2R
61357
2
0°
135°
Loose
16
Central FW pump no.1
VRF 9/350 G
61358
1
180°
270°
Loose
16
Central FW pump no.2
VRF 9/350 G
61359
1
0°
270°
Loose
16
Central FW pump no.3
VRF 9/350 G
61360
1
180°
270°
Loose
17
Ballast pump no.1
VRF 7/350S
61361
1
180°
270°
Loose
17
Ballast pump no.2
VRF 7/350S
61362
1
0°
270°
Loose
P1
Oily bilge pump
BS 50
61363
3
0°
90°
Loose
P2
Sludge pump
PL 300
61364
90°
90°
A
E1
Emergency fire pump
SFN 80
61365
2
180°
0°
B
H1
Hydrophore pump no.1
CR 5-9 F
61366
1
0°
0°
Loose
H1
Hydrophore pump no.2
CR 5-9 F
61367
1
0°
0°
Loose
Pos.
Service
Type
1
Main cooling SW pump no.1
VRF 9/350
1
Main cooling SW pump no.2
1
. o n l a i r e S
Design 8 : see outline drawing
16.02.2005
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun
HSHI 234
16.02.2005
Behrens Pumpen
Data sheet e-motor
Customer Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Newbuilding HSHI 234 Item
1
1
1
6
7
7
8
8
9
10
printed:
Pumptype Serial no.
Service
VRF 9/350 61344
Main cooling SW pump no.1
VRF 9/350 61345
Main cooling SW pump no.2
VRF 9/350 61346
Main cooling SW pump no.3
VRF 3/350 61347
FW generator ejector pump
VRF 7/350 61348
Bilge, Fire & GS pump no.1
VRF 7/350 61349
Bilge, Fire & GS pump no.2
VRF 7/290 G 61350
M/E JW cooling pump no.1
VRF 7/290 G 61351
M/E JW cooling pump no.2
SOH 222 W G 61352
M/E air cooler chemical cleaning pump
CSM 100L-4
UP 25-72/180 61353
Hot water circulating pump
.
16.02.2005
E-motortype
WEG CSM 280 S/
e r u s o l c n E
n o i t a l u s n I
r e t a e h e c a p S
0 0 1 T P
C T P x 3
e l p p i N M P S
Order no.: 224678
Classif. GL
Speed Motor Required Rated starting Starting Power eta rating shaft po. current current method factor cos φ [kW] [kW] [A] [A]
e t a c i f i t r [rpm] e C
IP 55
F to B
x
1780 105,00
85,70
163,0 1.080,0
direct
0,90 0,94
IP 55
F to B
x 1780 105,00
85,70
163,0 1.080,0
direct
0,90 0,94
IP 55
F to B
x
1780 105,00
85,70
163,0 1.080,0
direct
0,90 0,94
IP 55
F to B
1765
25,00
17,20
310,0
direct
0,86 0,92
IP 55
F to B
x
3570 125,00
80,00
193,0 1.467,0
direct
0,90 0,94
x
3570 125,00
193,0 1.467,0
direct
0,90 0,94
440V/60Hz WEG CSM 280 S/ 440V/60Hz WEG CSM 280 S/ 440V/60Hz WEG CSM 180 L-4
41,4
440V/60Hz WEG CSM 280 S/
104,00
440V/60Hz WEG CSM 280 S/
IP 55
F to B
104,00
440V/60Hz WEG CSM 200 L-4
IP 55
F to B
IP 55
F to B
IP 55
F to B
IP 55
F to B
80,00
1770
42,00
35,00
68,9
482,0
direct
0,87 0,92
1770
42,00
35,00
68,9
482,0
direct
0,87 0,92
1700
2,60
1,50
4,9
32,6
direct
0,85 0,82
3450
0,20
0,10
0,3
3 ,0
direct
440V/60Hz WEG CSM 200 L-4 440V/60Hz
440V/60Hz
440V/60Hz
Page 1 of 3
Behrens Pumpen
Data sheet e-motor
Customer Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Newbuilding HSHI 234 Item
11
11
15
15
16
16
16
17
17
P1
printed:
Pumptype Serial no.
Service
E-motortype
SFH 334 WW G 61354
Composite boiler feed water pump no.1
CSM 132S-4
SFH 334 WW G 61355
Composite boiler feed water pump no.2
CSM 132S-4
VAL 302/2R 61356
Main LO pump no.1
CSM 315S/M-4
VAL 302/2R 61357
Main LO pump no.2
VRF 9/350 G 61358
Central FW pump no.1
VRF 9/350 G 61359
Central FW pump no.2
VRF 9/350 G 61360
Central FW pump no.3
VRF 7/350S 61361
Ballast pump no.1
VRF 7/350S 61362
Ballast pump no.2
BS 50 61363
Oily bilge pump
16.02.2005
e r u s o l c n E
n o i t a l u s n I
IP 55
F to B
IP 55
F to B
IP 55
F to B
r e t a e h e c a p S
0 0 1 T P
C T P x 3
e l p p i N M P S
Order no.: 224678
Classif. GL
Speed Motor Required Rated starting Starting Power eta rating shaft po. current current method factor cos φ [kW] [kW] [A] [A]
e t a c i f i t r [rpm] e C
1760
6,60
5,50
11,3
90,6
direct
0,87 0,88
1760
6,60
5,50
11,3
90,6
direct
0,87 0,88
440V/60Hz
440V/60Hz
x
440V/60Hz CSM 315S/M-4
IP 55
x
F to B
440V/60Hz WEG CSM 280 S/
1780 230,00
147,00
30,00
192,00
1780
1780 230,00
147,00
1780
30,00
192,00
368,0 2.466,0 transfor
0,86 0,95 0,86
368,0 2.466,0 transfor
0,86 0,95 0,86
IP 55
F to B
x
1780
99,00
81,40
154,0 1.091,0
direct
0,90 0,94
IP 55
F to B
x
1780
99,00
81,40
154,0 1.091,0
direct
0,90 0,94
IP 55
F to B
x 1780
99,00
81,40
154,0 1.091,0
direct
0,90 0,94
IP 55
F to B
x
x
1775
63,00
54,20
97,3
729,0
direct
0,91 0,93
IP 55
F to B
x
x 1775
63,00
54,20
97,3
729,0
direct
0,91 0,93
IP 55
F to B
1700
2,60
1,50
4 ,9
32,6
direct
0,85 0,82
440V/60Hz WEG CSM 280 S/ 440V/60Hz WEG CSM 280 S/ 440V/60Hz WEG CSM 250 S/ 440V/60Hz WEG CSM 250 S/ 440V/60Hz CSM 100L-4 440V/60Hz
Page 2 of 3
Behrens Pumpen
Data sheet e-motor
Customer Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Newbuilding HSHI 234 Item
P2
E1
H1
H1
printed:
Pumptype Serial no.
Service
PL 300 61364
Sludge pump
SFN 80 61365
Emergency fire pump
CR 5-9 F 61366
Hydrophore pump no.1
CR 5-9 F 61367
Hydrophore pump no.2
16.02.2005
E-motortype
SK42-160M-4
e r u s o l c n E
n o i t a l u s n I
IP 55
F to B
IP 55
F to B
IP 55
F to B
IP 55
F to B
r e t a e h e c a p S
0 0 1 T P
C T P x 3
e l p p i N M P S
Order no.: 224678
Classif.
Speed Motor Required Rated starting Starting Power eta rating shaft po. current current method factor cos φ [kW] [kW] [A] [A]
e t a c i f i t r [rpm] e C
direct
1750
15,00
7,00
29,0
173,0
3555
34,00
29,00
54,2
406,0 transfor
3450
2,20
1,80
4,5
36,0
direct
3450
2,20
1,80
4,5
36,0
direct
440V/60Hz WEG CSM 200 L-2
x
440V/60Hz . 440V/60Hz . 440V/60Hz
Page 3 of 3
0,89 0,92
13/192
14/192
Behrens Pumpen Von-Thünen-Str.7 28307 Bremen Germany Tel.+49 (421) 48681-0 - Fax +49 (421) 48681-11 -
[email protected]
Regreasing int ervals Customer: HYUNDAI SAMHO Heavy Industries CO.,LTD. Projekt: S 232/ 233/ 234/ 235 Item No.
Purpose
Pump type
1 6 7 8 9 10 11 15 16 17 P1 P2 E1 H1
Main cooling sea water pump no.1-3 FW generator ejector pump Bilge, fire & GS pump no. 1+2 M/E J/W cooling pump no.1+2 M/E air cooler chem. clean pump Hot water circ. pump Composite boiler feed water pump no. 1+2 Main LO pump no. 1+2 Central FW pump no.1-3 Ballast pump no. 1+2 Oily bilge pump Sludge pump Emergency fire pump Hydrophore pump no.1+2
VRF 9/350 G VRF 3/350 G VRF 7/350 G VRF 7/290 G SOH 222 WG UP 25-72/180 SFH 334 WWG VAL 302/2R VRF 9/350 G VRF 7/350S G BS 50 PL 300 SFN 80 CR 5-9 F
Regreasing Interval (hours) 1200 1700 480 1500 life time life time life time 2000 1200 1500 life time life time 7000 life time
Regreasing Quantity (gram/bearing) 25 15 20 20
Point of application Motor/ Pump 2/2 0/2 2/2 2/2
20 25 25
2/0 2/2 2/2
8
0/2
As a lubricant, use quality rolling contact bearing greases having the following specification: Saponification basis: Lithium or Calcium-sulfonat with anti- corrosion additives, water repellent Handling temperatures -20°C up to +120°C Walk penetration: 250 to 295 Dropping Point: 180°C Standard: SEB 181252/ SEB 18103K3K
For all Pumps: Initialing filling done!
Behrens Pumpen SPARE PART & TOOL LIST
Customer Order
Hyundai Samho Heavy Industries Co. 224678
Project
HSHI 234 Item P1
Type: Service:
BS 50 Oily bilge pump
Serial no.: Spare parts
61363
Item
Qty
Name
1
set
packing
1
set
gaskets
1
pc. DUO-piston
1
set
valve springs
Item E1 Type: Service:
SFN 80 Emergency fire pump
Serial no.: Spare parts
61365
Item
Qty
321.1
1
pc. double deep groove ball bearing
321.2
1
pc. double deep groove ball bearing
461
1
set
Name
stuffing box packing ring
Tools:
Qty.
Name
1
grease gun
1
Spare part & Tool box
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 1
Service Type: Description
Main coolin SW um no.1 VRF 9/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61344
32 1030 940,00 -0,50 1,50 2,00 85,70 94,00 1780 5,50
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Bronze G-CuSn10 Duplex st steel Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Packing Ramie + PTFE DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29724 BH, T.P. 7 bar 02 GL 05 E-motor : 14842 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 105,00 163,00 1080,00
E-Motor Nr.
: QA 31571
PTC : SPM : no Space heater : no
Weights
885,00
/
802,00
Total
(kg)
: 1.687,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 1
Service Type: Description
Main coolin SW um no.2 VRF 9/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61345
32 1030 940,00 -0,50 1,50 2,00 85,70 94,00 1780 5,50
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Bronze G-CuSn10 Duplex st steel Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Packing Ramie + PTFE DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29725 BH, T.P. 7 bar 02 GL 05 E-motor : 14842 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 105,00 163,00 1080,00
E-Motor Nr.
: QA 31573
PTC : SPM : no Space heater : no
Weights
885,00
/
802,00
Total
(kg)
: 1.687,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 1
Service Type: Description
Main coolin SW um no.3 VRF 9/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61346
32 1030 940,00 -0,50 1,50 2,00 85,70 94,00 1780 5,50
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Bronze G-CuSn10 Duplex st steel Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Packing Ramie + PTFE DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29726 BH, T.P. 7 bar 02 GL 05 E-motor : 14842 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 105,00 163,00 1080,00
E-Motor Nr.
: QA 31575
PTC : SPM : no Space heater : no
Weights
885,00
/
802,00
Total
(kg)
: 1.687,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 1 of 8
3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 2 of 8
5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 161.1 211.1 230 320 322 332 341 360 400.1 420.1 421 452 461 502.1 502.2 524 554.1 554.2 554.3 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.1 902.2 902.3 902.4 903.1 903.2 903.3
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung V-Ring Simmerring Stopfbuc hsbri lle Stopfbuc hspackung Spaltri ng Spaltri ng Wellensch utzhü lse Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube Verschl ußschraube
Volute casing Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket V-ring Simmer ring Stuffing box gland Packing Wearin g rin g Wearin g rin g Shaft pro tect ion sleeve Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug Plug
Corps à volut e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joi nt à lèvres Anneau de retenue Bride de presse-étoupe Garnitu re Bague d`usu re Bague d`usu re Chemise d´arbre Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n Boucho n
Verschl ußschraube
Plug
Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 1
Behrens Pumpen Teil Item Benennung Repère 912.1 Entleerungss topfen
Designation
Dèsignation
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.1
Sechskant mut ter
Nut
Ecrou hexagonal
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.1
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 2
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 6
Service Type: Description
FW enerator e ector um VRF 3/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61347
32 1030 70,00 -0,50 4,30 4,80 17,20 20,80 1765 4,20
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible spacer Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 125 125
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
WEG CSM 180 L-4 IM V1, IP 55, ISO B DOL 440 / 60 25,00 41,40 310,00
E-Motor Nr.
: BP 07473
PTC : SPM : no Space heater : no
Weights
273,00
/
183,00
Total
(kg)
: 456,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 5 of 8
7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 6 of 8
9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 7 of 8
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 161.1 211.1 230 320 322 332 341 360 400.1 420.1 421 452 461 502.1 502.2 524 554.1 554.2 554.3 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.1 902.2 902.3 902.4 903.1 903.2 903.3
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung V-Ring Simmerring Stopfbuc hsbri lle Stopfbuc hspackung Spaltri ng Spaltri ng Wellensch utzhü lse Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube Verschl ußschraube
Volute casing Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket V-ring Simmer ring Stuffing box gland Packing Wearin g rin g Wearin g rin g Shaft pro tect ion sleeve Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug Plug
Corps à volut e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joi nt à lèvres Anneau de retenue Bride de presse-étoupe Garnitu re Bague d`usu re Bague d`usu re Chemise d´arbre Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n Boucho n
Verschl ußschraube
Plug
Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 1
Behrens Pumpen Teil Item Benennung Repère 912.1 Entleerungss topfen
Designation
Dèsignation
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.1
Sechskant mut ter
Nut
Ecrou hexagonal
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.1
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 2
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 7
Service Type: Description
Bil e, Fire & GS um no.1 VRF 7/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61348
32 1030 90,00 9,00 9,00 80,00 114,00 3570 6,10
280,00
-
3,00 3,00 104,00 114,00
-
6,50
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible spacer Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 200 200
PN 16 16
Type
: self-priming unit AELE - 45 level switch controlled, air driven selfpriming unit mounted on pump
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29727 BH, T.P. 15 bar 02 GL 05 E-motor : 14843 H 12 GL 04
Self-priming unit Prime mover
E-Motor
Power supply Power Rated current Starting current
WEG CSM 280 S/M-2 HO IM V1, IP 55, ISO B DOL 440 / 60 125,00 193,00 1467,00
E-Motor Nr.
: QA 31464
PTC : SPM : no Space heater : no
Weights
570,00
/
780,00
Total
(kg)
: 1.350,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 7
Service Type: Description
Bil e, Fire & GS um no.2 VRF 7/350 Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61349
32 1030 90,00 9,00 9,00 80,00 114,00 3570 6,10
280,00
-
3,00 3,00 104,00 114,00
-
6,50
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible spacer Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 200 200
PN 16 16
Type
: self-priming unit AELE - 45 level switch controlled, air driven selfpriming unit mounted on pump
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29728 BH, T.P. 15 bar 02 GL 05 E-motor : 14843 H 12 GL 04
Self-priming unit Prime mover
E-Motor
Power supply Power Rated current Starting current
WEG CSM 280 S/M-2 HO IM V1, IP 55, ISO B DOL 440 / 60 125,00 193,00 1467,00
E-Motor Nr.
: QA 31463
PTC : SPM : no Space heater : no
Weights
570,00
/
780,00
Total
(kg)
: 1.350,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 1 of 8
3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 2 of 8
5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 4 of 8
6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 5 of 8
7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 6 of 8
9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 7 of 8
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 161.1 211.1 230 320 322 332 341 360 400.1 420.1 421 452 461 502.1 502.2 524 554.1 554.2 554.3 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.1 902.2 902.3 902.4 903.1 903.2 903.3
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung V-Ring Simmerring Stopfbuc hsbri lle Stopfbuc hspackung Spaltri ng Spaltri ng Wellensch utzhü lse Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube Verschl ußschraube
Volute casing Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket V-ring Simmer ring Stuffing box gland Packing Wearin g rin g Wearin g rin g Shaft pro tect ion sleeve Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug Plug
Corps à volut e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joi nt à lèvres Anneau de retenue Bride de presse-étoupe Garnitu re Bague d`usu re Bague d`usu re Chemise d´arbre Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n Boucho n
Verschl ußschraube
Plug
Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 1
Behrens Pumpen Teil Item Benennung Repère 912.1 Entleerungss topfen
Designation
Dèsignation
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.1
Sechskant mut ter
Nut
Ecrou hexagonal
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.1
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 2
TYP/TYPE AELE 35/45/55/65
PD-AELE-11-BEHRENS-GB.DOC
Table of contents 1 Commissioning 2
Maintenance and repair
2.1 Disassembly and assembly of the compressed air ejector 2.2 Disassembly and assembly of the jet system 2.3 Disassembly and assembly of the shut-off system 3
Appendix
3.1 Dimensions 3.2 Spare parts 3.2 Circuit Diagramm
Operating voltage Enclosure Power input Nominal pressure Compressed working air required Material: Float chamber Ejector casing Nozzle system Inner parts Sealings Size of Nozzle: Suction capacity max. Air consumption at 6 bar Pressure-Stage: Switch-on Point Switch-off Point
220V-230V 50/60 Hz IP65 16 VA PN 10 5 - 7 bar Bronze GCuSn10 Bronze GCuSn10 Polyetylene Stainless Steel NBR 35 Nl/min 300 l/min 70 bar bar
Connections: Venting suction side Venting discharge side Exhaust, Drainage Pressure switch Cable Compressed working air
1
45 500 120 U 0,3 0,5
55 700 180 V 0,6 1,1
A1 A2 B C E P
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
65 1000 240 W 1,1 1,6
TYP/TYPE AELE 35/45/55/65
1.
PD-AELE-11-BEHRENS-GB.DOC
Commissioning
For commissioning pay attention to following steps: - Check all pipe connections and pipes for proper lay and leakage. - Check all electrical connections. - Check the compressed air connection Caution Please pay attention to modification for special design. 2.
Maintenance and repair
The system functions with slightly maintenance work. Following inspections respectively work should be performed in fixed intervals which depend on pumping medium, operation mode and operation time. - Check all components for proper function 2.1 Disassembly and assembly of the compressed air ejector
Before starting work, the compressed air ejector must be switched to a power off mode.
Before starting work, the compressed air ejector must be disconnected from the compressed air supply. Starting torque for the thread connections are to be taken from the corresponding DIN-Norm. Caution We advise to exchange all sealings at repair work. Disassembly of the compressed air ejector: - Take off cable plug at the solenoid valve of the compressed air ejector. - Loosen the exhaust and compressed air pipe. - Loosen the assembling screws of the compressed air ejector and remove the compressed air ejector Assembly takes place in reversed order. 2.2 Disassembly and assembly of the jet system - Fix the compressed air ejector and turn out the long nibble. - Pull out the mixing jet of the casing - Take out the driving jet of the casing. Assembly takes place in reversed order. Caution The long nipple has to be screwed on the casing powerful. The check nut may not to be twisted.The long nipple must be fitted with a bolt protection medium (e.g. Loctite). 2.3 Disassembly and assembly of the shut-off valve - Loosen the pressure switch casing at the compressed air ejector
Pressure switch casing is spring pressurized. -
Take out the compression spring and loosen the safety nut at the spring seating. Use the safety nut at the piston (jet side) for supporting. - Take out spring seating, guide ring and valve seling of the compressed air ejektor. - Take out the Piston rod with mounted piston. Assembly takes place in reversed order. Caution When assembling the piston the gasket is to be pressed via compressed air supply by a similar formed tool. vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
2
TYP/TYPE AELE 35/45/55/65
3.
Appendix
3.1 Dimensions
13413d/A4
3
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
PD-AELE-11-BEHRENS-GB.DOC
TYP/TYPE AELE 35/45/55/65
PD-AELE-11-BEHRENS-GB.DOC
3.2 Spare parts
14153b/A4
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
4
TYP/TYPE AELE 35/45/55/65
3.3 Circuit diagramm Circuit diagramm of the aspirator
Recommended connecting plan for time delayed starting of the centrifugal pumps.
30176/A3
5
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
PD-AELE-11-BEHRENS-GB.DOC
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 8
Service Type: Description
M/E JW coolin um no.1 VRF 7/290 G Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61350
80 1000 295,00 1,50 4,50 3,00 35,00 40,00 1770 4,10
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Mechanical seal Carbon-SiC EPDM DN 200 200
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump Pump : 29729 BH, T.P. 6 bar 02 GL 05
Power supply Power Rated current Starting current
WEG CSM 200 L-4 IM V1, IP 55, ISO B DOL 440 / 60 42,00 68,90 482,00
E-Motor Nr.
: BP 11823
PTC : SPM : no Space heater : no
Weights
350,00
/
260,00
Total
(kg)
: 610,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 8
Service Type: Description
M/E JW coolin um no.2 VRF 7/290 G Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61351
80 1000 295,00 1,50 4,50 3,00 35,00 40,00 1770 4,10
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Mechanical seal Carbon-SiC EPDM DN 200 200
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump Pump : 29730 BH, T.P. 6 bar 02 GL 05
Power supply Power Rated current Starting current
WEG CSM 200 L-4 IM V1, IP 55, ISO B DOL 440 / 60 42,00 68,90 482,00
E-Motor Nr.
: BP 11822
PTC : SPM : no Space heater : no
Weights
350,00
/
260,00
Total
(kg)
: 610,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 1 of 8
3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 2 of 8
5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 4 of 8
6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 5 of 8
7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 6 of 8
9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 7 of 8
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 160 161.2 211.2 230 320 322 332 341 360 400.1 400.2 420.1 420.2 421 470 502.1 502.2 540 554.1 554.2 554.3 554.4 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.2 902.3 902.4 902.5 903.1
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Deckel Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung Flachdichtung V-Ring V-Ring Simmerring Gleitringdic htung Spaltri ng Spaltri ng Buchs e Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube
Volute casing Cover Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket Gasket V-ring V-ring Simmer ring Mechanical seal Wearin g rin g Wearin g rin g Bush Washer Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug
Corps à volut e Couvercl e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joint Joi nt à lèvres Joi nt à lèvres Anneau de retenue Garnitu re mécanique Bague d`usu re Bague d`usu re Douille Disque Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014G Blatt 1
Behrens Pumpen Teil Item Benennung Repère 903.2 Verschl ußschraube
Designation
Dèsignation
Plug
Boucho n
903.3
Verschl ußschraube
Plug
Boucho n
912.1
Entleerungss topfen
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
920.5
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.3
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014G Blatt 2
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 9
Service Type: Description
M/E air cooler chemical cleanin SOH 222 W G Side channel pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
um
61352
60 1000 5,00 -0,50 2,50 3,00 1,50 2,50 1700 2,40
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Brass Stainless steel Rolling contact grease Mechanical seal C-SiC FKM DN R 1 1/4" R 1 1/4"
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
CSM 100L-4 IM B3, IP 55, ISO B DOL 440 / 60 2,60 4,87 32,60
PTC : SPM : no Space heater : no
Weights
32,00
/
32,00
Total
(kg)
: 64,00
16.02.2005
Operating instructions VKO/VKR 110-550
W(W)
Ident. no.: Serial no.: Contents 0. Brief instructions 1. General Application 2. Safety 3. Transportation and temporary storage Preservation 4. Description Structural design 5. Planning the system Pipes, safety equipment 6. Installing the pump Safety measures 7. Start-up / shut-down 8. Maintenance 9. Servicing, disassembly, reassembly Spare parts, standby pumps 10. Faults; causes and correction 11. Associated documents 12. Pump identification
18.09.03
This pump may only be installed and brought into service by trained personnel, who must precisely follow these operating instructions and the applicable legal requirements. If these operating instructions are not followed: you may be putting yourself or your colleagues at risk, the pump or the pump unit may be damaged, and the manufacturer will not be liable for any resulting damage! When working on the pump or pump unit, please remember that you are responsible for the safety of your colleagues!
These operating instructions conform to the provisions of EN292 part 2, sub-section 5.5 and the safety regulation EN809.
K00V0001.ENG
0.
Brief instructions on starting up a pump unit supplied complete
The pumped liquids must not have a tendency to crystallise out and must contain no potentially abrasive solids (see section 1.1 Application).
Remove the protective caps from the pipe sockets before connecting the pipes.
If the pump has been preserved, drain off the preservative agent (dispose of correctly) and clean the pump.
Align the pump or pump unit on the foundation and fix in place.
Clean the pipes.
Note the directions of flow and rotation (see arrows on the pump).
Fill the pump with liquid (the pump must have been thoroughly vented).
Open all the shut-off devices in the inlet and discharge pipes.
Check that the coupling guard is fitted and all the safety equipment is ready for operation.
Fit a motor circuit-breaker. The electrical connection work may only be carried out by a qualified electrician. Check the voltage, speed and direction of rotation.
Turn the unit manually and ensure that it is running smoothly and evenly.
Switch on the motor.
Once it has run up to operational speed, check the operating pressure on the manometer and set the operating point by restricting the pressure on the discharge side, if necessary.
Do not allow the flow to fall below the minimum value.
The pump must be constantly supplied with fluid. It must never be allowed to run dry.
Never touch a pump while it is running - it may be hot/cold.
The power consumption increases as the pump head rises and the amount of liquid pumped decreases.
The pump must never be started up or operated when the inlet and/or discharge pipe is closed.
During assembly or operation, the pipes must not transmit stresses to the pump.
The safety instructions specified under point 2-ff must be followed.
02.10.95
K01V0001.ENG
1.
General
1.1
Application
1.3
Characteristics of side channel pumps
This is a self-priming side channel pump. It is suitable for pumping pure, cloudy and gaseous liquids containing no abrasives (size not larger than 0,1 mm). In design, it corresponds to a multistage ring section pump. The use of standardised components for several pump series and sizes makes it economical to keep a stock of standby parts and to purchase spare parts. The pump is driven by an electric motor. The pump should be used only under the operating conditions specified by the customer and confirmed by the supplier. The correct and intended application is specified in the data sheet supplied with the pump, a copy of which is shown in the appendix.
Fig. 1.1
The pump must only be used for the application specified in the data sheet. Otherwise, it may endanger both people and the environment. Do not allow the specific gravity to fall below or exceed the value specified in the data sheet, since this could result in damage to the pump.
Systems in which a failure or malfunction could lead to injury or damage should be fitted with alarm systems and/or standby units and should be checked at regular intervals to ensure that they are in good working order.
Fig. 1.2
Units which are directly or indirectly linked to drinking water supplies should be thoroughly cleaned before installation and start-up to remove all impurities.
Never touch a pump while it is in use - it may be hot. The data relating to speed, pressure and temperature contained in the data sheet are values at which correct functioning of the pump is guaranteed. It is essential to adhere to these values. Fig. 1.3
Requirements: If the outlet side of a pump is closed while the pump is running, the temperature of the liquid in the pump may rise to a dangerous degree. Dangers may arise from overpressure and subsequent failure of part of the pump or pipework. Particular dangers arise if the liquid being pumped is flammable, as it will be more easily ignited at increased temperatures. Explosions may occur if the liquid is chemically unstable when overheated. These dangers are commonly prevented by providing a liquid return loop incorporating a pressure relief valve. It is also important not to fall below the specified inlet pressures (system pressures). If the order confirmation does not specify any pressures and/or temperatures, then the limit pressures and temperatures specified in the brochure apply, provided that no further restrictions are imposed by the type of shaft seal used.
1.2
Testing
All our pumps undergo extensive testing on the test bench before they leave the factory. Only pumps which are running perfectly and achieve the promised performance levels, taking account of the specified tolerances, are allowed to leave the factory. If these operating instructions are followed, we guarantee fault-free operation and full pumping capacity. Test pressure = 1.5 x pump operating pressure 02.10.95
1. Start up with the valves open. 2. Never work with the discharge pipe closed. 3. Only work within the range from Qmin to Qmax.
1.4
Guarantee
Our liability for defects in the goods supplied is set out in our delivery conditions. We accept no liability for damage caused by not following the operating instructions or not observing the conditions for use. If the operational conditions subsequently change (e.g. different liquid to be pumped, different speed, viscosity, temperature or inlet conditions), then we must be given an opportunity to investigate the individual case and, if necessary, to confirm whether the pump is suitable for the intended purpose. Unless special arrangements are made, pumps supplied by us may only be opened or modified by us or by our authorised service partners during the guarantee period. Otherwise, we will not be liable for any defects.
K01V0001.ENG
1.5
Noise level
Depending on the pump size, the noise from our pumps falls within the range from 60 to 72 dB(A).
Expected noise values of side channel pumps at a speed of n=1450 1/min 75 ] ) A ( b d [
70
A
L l e v e l
65
e r u s s e r p e s i o N
60
55
50
45 1
10
Power P [kW]
Fig. 1.4
However, the pump is not necessarily the only possible source of irritating noise. Other noise. Other possible sources of noise are:
the drive
the coupling, coupling, which which may be been been fitted incorrectly
other devices devices in in the same area (e.g. heating heating system) system)
the water pipes, cocks or valves. valves. Flowing Flowing water always causes causes noise (e.g. water hammer). However, such noise may be reduced by suitable measures, so that it no longer causes a disturbance.
The water flow speed should be kept as low as possible. Large pipes, pressure reducers and other devices are particularly suitable for reducing the flow speed. If the pump is the major source of noise, the noise can be deadened by the following measures: 1. Place the pump pump on rubber buffers. 2. Insert a rubber connector into the inlet and discharge pipes, pipes, between the pump and the pipes. 3. Do not allow allow pipes to come into direct direct contact with walls, ceilings ceilings or floors. 4. If necessary, enclose the pump (but not the motor) in in a soundproof enclosure.
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K02V0001.ENG
2.
2.4
Safet y
These operating instructions contain fundamental information which must be followed during installation, operation and maintenance. Consequently, before assembly and start-up, these operating instructions must be read by the mechanic and the competent technical personnel / operators, and must be available at all times in the vicinity of the machine / system. In addition to the safety instructions given in this section, the other special safety instructions (e.g. for private use) given in other sections must also be followed. Local safety regulations will not be superseded by these operating instructions.
2.1
Ide Identific fication ion of instructions in these operating instructions
If certain safety instructions in these operating instructions are not followed, there could be a risk to personal safety. These instructions are identified by the general hazard symbol:
Safety symbol according to ISO 3864-B.3.1 In the case of warnings about electrical voltage, the safety instructions are identified by:
Safety symbol according to ISO 3864-B.3.6 For safety instructions which, if they are not followed, could endanger the machine and its functioning, the word WARNING is inserted. Instructions attached to the machine, such as the direction of rotation arrows or liquid connection markers, must be followed and must be fully legible at all times.
2.2
Personnel qu qualifications and training
The operating, maintenance, inspection and assembly personnel must have the appropriate qualifications for this work. The area of responsibility, competence and staff supervision must be precisely stipulated by the owner. If none of the personnel has the necessary experience or knowledge, then they must be given training and instruction. If necessary, this can be provided by the manufacturer/supplier at the machine owner’s request. The machine owner should also ensure that the content of the operating instructions is fully understood by his employees.
2.3
Risks if if th the sa safety ins instructions ar are not observed
Failure to observe the safety instructions can endanger people, the environment and the machine. Any claims for damages may be invalidated if the safety instructions are not followed. Failuire to observe the safety instructions can, for example, lead to the following risks:
Failure of important machine/system functions
Failure of prescribed prescribed maintenance and repair repair methods methods
Lives may be put at risk by electrical, mechanical mechanical and chemical hazards.
Risk to the environment environment caused by the leaking of hazardous hazardous materials.
02.10.95
Safe working practices
The safety instructions given in these operating instructions, the applicable national accident prevention regulations and the owner’s internal working, operational and safety regulations should be followed.
2.5
Safety ins instruction ions for the own owne er / operator
If hot or cold machine parts represent represent a potential risk, these parts parts must be protected on site against accidental contact.
Protective devices devices on moving parts parts to prevent prevent accidental accidental contact (e.g. coupling guard) must not be removed while the machine is in use.
Leaks (e.g. from the the shaft seal) of hazardous hazardous (e.g. explosive, explosive, poisonous, hot) liquids must be eliminated so that they do not endanger life or the environment. The legal regulations must be observed.
Measures should should be taken to prevent the risk of electric shock (for further information on this subject, see the VDE regulations and those of t he local electricity company, for example).
2.6
Safety instructions for maintenance, inspection and assembly work
The owner must ensure that all maintenance, inspection and assembly work is carried out by authorised and qualified technical staff who have read and understood the operating instructions. Work must only be carried out when the machine is shut down. The procedure for shutting down the machine described in the operating instructions MUST be followed. Pumps or pump units containing media which are a potential hazard to health must be decontaminated. Pumps sent to us for repair should be cleaned beforehand so that they do not represent a hazard to the health of our employees. As soon as the work has ended, all safety and protective devices must be replaced or brought into service once more. Sections 7.1, 7.3 and 7.4.2 must be followed before starting up the machine again.
2.7
Conversion and production of spare parts by the owner
The machine may not be converted or modified without the manufacturer’s prior approval. The use of original spare parts and accessories authorised by the manufacturer ensure operational safety. The use of other parts may invalidate our liability for any resulting damage.
2.8
Inadmiss issible operating methods
The operational safety of the machine can only be guaranteed if it is used in the manner intended, as described in Section 1 General of these operating instructions. The limit values specified in the data sheet must not be exceeded under any circumstances.
K03V0008.eng
3.
Transportation and temporary storage
3.1
Safety measures
Never stand beneath a suspended load. Always keep a safe distance from the load while it is being moved. Only use the prescribed lifting tools and ensure that they are in perfect condition.
Fig. 3.2 Close-coupled pump
Adjust the length of the lifting devices so that the pump or unit is suspended horizontally. Do not remove any documents that are attached to the pump. Always handle the pump with care.
3.2
Packaging
The symbols on the packaging should be observed. The inlet and discharge sides of the pump must be closed off with caps during transportation and storage. When installing the pump unit, the flange caps should be removed.
3.3
Unpacking
Before unpacking, carry out a visual inspection of the packaging. If any damage has occurred during transportation, note the extent of the damage on the receipt or delivery note. Any claims should be made immediately to the carrier company or carriage insurance company.
3.4
Temporary st storage
If the pump or unit is not installed immediately upon delivery, the machine must be st ored frost-free in a dry and vibration-free area.
3.5
Transportation
The pump must be transported correctly. Fig. 3.1 – 3.3 are showing the correct handling methods.
When moving the pump unit using a crane, the crane and slings must be of a suitable size. The slings must not be attached to the motor eyes.
Fig. 3.3 Vertical pump
3.6
Preservation
If we have applied a preservative agent at the factory, this will be brought to the user’s attention: 1. On the the plate plate attached attached to the pump 2. By way of a notice on the delivery delivery note note and invoice. invoice. The preservative agent will last for 6 months. Please note that all pumps made from cast iron or spheroidal graphite cast iron that are brought into service (even for a trial run) must be corrosion protected when they are shut down again. A preservative agent should be applied both internally and externally, following the instructions in sections 3.6.1 + 3.6.2.
3.6. 3.6.1 1
Pres Preser erv vativ tive agen agentt
The preservative agent specified below may be used for both external and internal preservation.
Fig. 3.1 Pump with motor on a base plate
Preservative-agent: FINA BIOHYDRAN TMP 32, Total Fina Deutschland GmbH, 40217 Düsseldorf
For external preservation, preservation, all blank and unpainted parts, such as shaft ends, flange surfaces, are preserved. Apply the preservative agent using a brush or spray gun. For internal preservation, preservation, the inside of the casing, shaft, impellers and the shaft seal are preserved. Introduce the preservative agent by filling the pump. During the filling operation, turn the shaft slowly in the direction of rotation. Continue filling until the preservative agent reaches the sealing strips of the inlet and discharge flanges. Then, close the pressure and inlet sides using a blanking flange. NOTE: The specified preservative agent should be regarded as a recommendation. Preservative agents with equivalent preservative characteristics from other mineral oil manufacturers may also be used.
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K03V0008.eng
According to the preservative agent manufacturer’s specifications, the preservative agent will last for 6 months. The effective ingredients of the preservative agent also provide adequate corrosion protection in areas with increased atmospheric humidity (at sea, tropical climate).
3.6. 3.6.2 2
Remo Remov val and and dis dispo posa sall of of the the preservative preservative agent
Before start-up, the preservative agent must be removed. The preservative agent introduced for internal preservation must be drained off.
Preservative agents must be disposed of correctly. The pump must be cleaned completely. This is of particular importance for pumps which are used in the food or drinking water supply industries. A suitable solvent which is compatible with the pumped liquid (and with foodstuffs) may be used as the cleaning agent for removing the internal and external preservation.
3.7
Long-term stor torage and monito itoring the preservation
If the pump is stored for long periods, the owner must check the preservation at regular intervals. The fill level of the pump should be checked every 6 months. If necessary, the preservative agent is topped up to the sealing strip on the discharge flange resp. to be renewed.
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K04V0003.ENG
4.
Description
4.1
Structural de design
Self-priming ring section pump which acts as a side channel pump. The capacity of the side channel pump is dependent, in particular, on the gap between the impeller and stage casing (0.15 to 0.17 mm). Given the narrow clearances, the pump is not suitable for pumping media containing solids (in certain cases, a filter should be provided on the inlet side).
4.2
Casing
The joints between the casing and sides on the inlet and discharge sides run transversely. The casing and casing parts are sealed with respect to one another by means of gaskets.
4.3
Pipe ipe sockets / fla flan nges / di dimension ions
See data sheet.
4.4
Connecting auxiliaries
In the discharge casing, the pumps contain:
1 screw-in screw-in plug for connecting a manometer. manometer.
1 screw-in screw-in plug for draining off the liquid.
In the inlet casing, the pumps contain:
1 screw-in screw-in plug for connecting connecting a mano / vacuummeter.
1 screw-in screw-in plug for draining draining off the liquid (complete (complete drainage is not possible).
4.5
Impellers
These are open, star-shaped wheels which compensate for axial thrust by means of relief holes.
4.6
Shaft
The pump is equipped with a particularly rigid shaft, which ensures fault-free operation under all load phases.
4.7
Bearings and seals
See data sheet.
4.8
Drive
The pumps are driven by an electric motor. In most cases the motors used are fan-cooled three-phase AC squirrel cage motors, model B3 or B14, type of protection IP44/54 to IEC standards, insulation class B, motor winding for 380 V or 660 V, 50 or 60 Hz. Explosion-proof motors and other design versions may also be used.
4.9
Coupling ing an and pr protective de devices to to prevent accidental contact
For our pumps, we use a flexible elastic coupling made coupling made by Flender, type N-Eupex, model B. Important information for fitting the coupling: Only use couplings where the pump-side coupling end can be connected to the nut on the shaft end in the axial plane. Turn or machine the hole in the hub of the pump-side coupling end so that the coupling halves can be slid on the shaft end without strong resistance. Do not hit with a hammer.
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In order to prevent accidents, the coupling must be secured with a protective device in accordance with DIN 31001 to prevent accidental contact. When pumping explosive materials, the protective device must be made from a material which does not produce sparks (e.g.: brass).
4.10
Accessories
A list of the accessories supplied with the pump is given in the data sheet. The associated operating and installation instructions are also given in the appendix. If you wish to fit other accessories to the pump or pump unit, please notify the manufacturer of the accessories you plan to use.
K05V0001.ENG
5.
Planning the system
5.1
Piping system Note the flow arrows on the pump’s pipe
sockets. Select the nominal diameters of the pipes so that they correspond to the nominal diameters of the pipe sockets (see data sheet). Do not forget to clean the pipes before they are installed. Support the pipes to ensure that no stresses are transferred to the pump (which could result in broken pump components). Avoid sudden changes in cross-section and direction. Compensate Compensate for differences in nominal diameter using eccentric transitions, thus preventing air pockets forming in the pipe.
Do not dispose of corrosion protection agents in the sewage system.
5.2
Inlet pipe
In order to guarantee cavitation-free operation, the instructions in Section 5.4 Inlet conditions must be followed. The inlet pipe can be laid in any form. It may pass over the pump since the liquid can also be sucked over the top. The cross-section of the inlet pipe must not be smaller than the pump’s suction pipe socket. Every effort should be made to achieve a flow speed of 1 m/sec in the suction pipe. pipe. Under particularly difficult pumping conditions, we also recommend providing a calming section on the suction side, upstream of the entry to the pump. The length of this calming section should be 10 x the pipe diameter. In suction mode, the suction strainer should be at least 0.2 m below the lowest level of the liquid (see fig. 5.1).
Upstream of the pump’s inlet pipe socket, install a calming section with the same diameter as the nominal diameter of the inlet socket and ten times as long as the inlet socket diameter. This will prevent cavitation. The flow speed in the inlet and feed pipes should not exceed 1 m/sec.
5.1.1
Nominal diam iameter
The size of the pipes must guarantee perfect flow conditions in the pump and thus have no detrimental effect on the functioning of the pump. Every effort should be made to ensure that the flow speed in the inlet and discharge pipes does not exceed 1 m/sec. Particular attention should be paid to the air-tightness of the inlet pipe and observing the NPSH values.
5.1. 5.1.2 2
Chan Change ges s in in cro cross ss-s -sec ecti tion on and and direction
The flow direction through the body of the pump is indicated by arrows on the pump casing.
Fig. 5.1 Non-return valve Suction strainer (Non-return valve)
Sudden changes in cross-section and direction and excessively sharp bends should be avoided.
5.1. 5.1.3 3
Supp Suppor orti ting ng ele eleme ment nts s and and flan flange ged d connections
Ensure that all pipes sockets are stress-free. The pipes should be supported in the vicinity of the pump and screwed loosely in place to prevent distortion. After loosening the screws, the flanges should not stand at an angle or spring back and should not be under pressure on both sides. Any thermal stresses on the pipe should be kept away from the pump by suitable measures, for example by fitting compensators. Hydraulic forces should also be absorbed by suitable pipe fasteners upstream and downstream of the pump. The pump has to be decoupled from the system and environment in respect to vibrations.
5.1.4 .1.4
Clea Cleani nin ng th the pip pipe e bef befo ore installation
It is important to ensure that the pipes are completely clean when they are brought into service. They must be free of weld beads, burrs, rust, etc. Flange seals must not project inwards. The sockets should be checked to ensure that they are air-tight (see Section 3.6 Preservation ).
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In order to maintain its self-priming capacity, the pump must always be filled with the liquid to be pumped. The side channel pump is able to carry air or gases and to evacuate a suction pipe. The pumps must be filled with liquid. The suction capacity is restricted to a vacuumetric suction lift of approximately 7 m (for water at 20° C) and decreases as the wear increases. The priming time should be limited to 1 minute at most, since the priming stagnates when the medium in the pump heats up. A non-return valve should be fitted in order to avoid having to lift out the pump after switching off (see fig. 5.1). For inlet operation, ensure that the liquid level remains at least 0.5 m above the pipe socket. For supplying liquid from a tank under vacuum, we recommend installing a compensation line (CL) (see Fig. 5.2).
K05V0001.ENG
5. When running two pumps in parallel, both pumps should be allocated a separate inlet pipe (see fig. 5.3). 6. Never connect the inlet pipe vertically to the feed tanks. It should always be horizontal in order to prevent the formation of eddy currents (see fig. 5.3).
Fig. 5.3 Wrong Right Fig. 5.2 Non-return valve
5.3
Discharge pipe
A constant cross-section of the pipes is also desirable on the discharge side. For a large pump head and long discharge pipes, it is sensible to fit a gently closing non-return element on the discharge side (non-return valve) (see fig. 5.1 + 5.2).
5.4
Supply conditions (NPSH)
In order to guarantee fault-free continuous operation, the inlet and suction conditions of the system should be matched to the pumping demand (NPSH). The operating conditions are fulfilled if the system NPSH value (NPSHavail) is greater than the pump NPSH value (NPSHreq.). NPSHavail. > NPSHreq.
7. Take precautionary measures to ensure that the feed pump can never run dry. 8. In the case of extremely large pumps, fit a regulating valve in the discharge pipe. 9. In the inlet and discharge pipe, allow for the installation of compensators. In addition, provision should be made for a filter in the inlet pipe and a non-return valve in the discharge pipe (see fig.5.3). 10. Do not fit quantity-dependent control valves in the pump’s discharge pipe. 11. When designing the system, the poorest NPSH value at the lowest possible pumping pressure should be taken into account. 12. Provide pressure measuring devices on the inlet and discharge sides. 13. Design the slide values in the inlet and discharge pipes so that they cannot be unintentionally closed. 14. If the pressure differential is sm aller than that intended, the NPSH range for the feed pump will not be so good. In order to prevent damage, the pump should be restricted accordingly (see fig. 5.4).
The (NPSHreq.) for each type of pump is given in the characteristic curves. Upon request, we can send you a special leaflet on calculating the NPSH values. During inlet operation, it is important to ensure that the geodetic suction lift of 7 m (for water at 20° C) is not exceeded. Please note that, with media with low vaporisation pressures or water at a temperature greater than 20° C, the suction lift of the pump will decrease accordingly. When pumping liquids at close to boiling point, watch the NPSH value and the inlet height since this could lead to cavitation in the pump, which will damage the hydraulic system.
5.5
Notes on planning and constructing boiler installations
1. Design the feed pump with an appropriate reserve in accordance with TRD 401. 2. If there are two possible types of pump, the best option is always to use the pump with the better NPSH value. 3. The length of the inlet and discharge pipes of the boiler feed pump should be kept as short as possible, and the number of elbows and bends kept to a minimum. 4. The inlet pipe should be a nominal diameter size larger than the socket on the inlet casing. Do not make sudden reductions in the pipe diameter.
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Fig. 5.4 Pressure falling NPSH rising
5.6
Safety equipment
Speed, pressure and temperature Suitable safety measures must be taken on site to ensure that the speed, pressure and temperature cannot exceed the limit values specified in the data sheet (see DIN 24295, Point 3.4). Sealing, purging and cooling Suitable regulating and monitoring options should be provided for any purging or sealing systems which may be fitted. For the required quantities and pressures, see the description of the shaft seals (see Section 8 Maintenance). In the case of dangerous media or high temperatures, care should be taken to ensure that the pump will shut down if the sealing or purging system fails. The sealing and purging systems must always be switched on before the pump is started up. They should not be switched off until the pump has stopped completely, if this is permitted by the type of operation (see Section 7 Start-up and shut-down).
K05V0001.ENG
Minimum quantities, working range The working range specified in the characteristic curve sheets should be used and the pump should not exceed or fall below this range during operation. The left-hand limit on the characteristic curve represents the minimum quantity for the pump. Suitable measures, such as freewheel non-return valves or a by-pass line, should be provided on site in order to guarantee the minimum quantity for the pump under all operating conditions. Ensure that the transfer capacity is not exceeded. If required, we will be pleased to help you with the design of the freewheel non-return valves or by-pass line. The inlet and discharge sides of the pump should each be equipped with a mano/vacuummeter or manometer. In order to be able to maintain the pump head precisely (see rating plate), a regulating valve should be provided on the discharge side. For larger pump heads (> 20 m), long pipes, parallel operation and system counterpressure, a non-return valve (R) should be installed on the discharge side in order to prevent back-flow through the pump when the unit is switched off (see fig. 5.1 + 5.2).
5.7
Electrical connections
The power supply cable for the driving motor should be connected by a qualified electrician in accordance with the motor manufacturer’s circuit diagram. The applicable VDE regulations and the regulations of the local electricity company should be observed. All risks of electric shock should be eliminated.
5.8
Inspection
Once installation is complete, all the pipes and sockets should be tested to ensure they are airtight. The unit should be tested to ensure that it is free of blockages (It should be possible to turn the shaft assembly by hand).
The operational safety of the installation (electrical connections, coupling guards, etc.) should be checked with reference to the applicable accident prevention regulations.
5.9
Hydrostatic pressure test
When carrying out a hydrostatic pressure test on the piping systems, the pump should be excluded from the test. If the pipes cannot be pressure tested without the pump, care should be taken to ensure that no foreign bodies enter the pump. The maximum pressure that may be applied to the pump during the test is 1.3 times the design pressure of the pump . The design pressure is given in the data sheet in the appendix. In the case of pumps with a gland, the packing should be replaced after the pressure test (since it will be compressed too much and will no longer be suitable for use). When emptying the pipe after the pressure test, a preservative agent should be applied to the pump (to avoid rusting and problems during start-up). The pipes must be connected to the pump so that the reaction forces which occur on the pipes never exceed the maximum admissible forces and torques at the pipe sockets. Before start-up, the piping system and installed fittings, devices, etc must be cleaned of impurities such as weld beads, scale, etc.
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K06V0001.ENG
6.
Installing the pump
2. Tighten the pump feet and motor feet. The feet should only be hand tight.
6.1
Safety measures
6.3.6
Checking the flexible coupling
After connecting the pipes, the alignment of the coupling must be checked, and adjusted if necessary. Carefully connect the pipes in order to prevent the medium used leaking out during pumping and endangering the operators. Ensure that the inlet and feed pipes and the discharge pipe are closed off.
Ensure that all the electrical connections are switched off in order to prevent potentially fatal electric shocks.
6.2
Fig. 6.1 Aligning with a straight-edge
Assembly tools
No special tools are required for setting up and installation.
6.3
Initial installation
6.3.1
Ambient conditions
The ambient temperature may be between -20° C and +40° C. The air humidity should be as low as possible in order to prevent corrosion.
6.3.2
Sub-floor and foundation
The pump must stand on a flat, vibration-free floor or foundation. In cases of doubt, vibration-damping feet should be used.
6.3.3
Fig 6.2 Aligning with a dial test indicator
Spatial requirements
The spatial requirements of the pump unit are given in the table of dimensions. Ensure that there are no obstructions to prevent access to the shut-off and control valves and to the m easuring devices. Sufficient space should be provided for maintenance and repair work, particularly for replacing the drive motor or entire pump unit.
6.3.4
Pre-installation checks
Before incorporating the pump into the system, the following points should be checked:
Has the drive motor been switched off?
Have the inlet, feed and discharge pipes been drained and closed off?
Can the pump be easily turned by hand (by turning the impeller on the motor)?
Have all the internal company regulations been followed?
6.3.5
Installing the pump and incorporating it into the piping system
Align the pump with the pipes. The pipes should be supported so that, when the pump is connected, no twisting can occur. When tightening the screws, follow the sequence given below: 1. Tighten the flanged connections. Remove the protective caps from the connectors before connecting the pipe. 02.10.95
Fig. 6.3 Aligning with a dial test indicator
Admissible misalignment for flexible couplings (only applies to original couplings supplied by us):
K06V0001.ENG
Size
1(58) 2(68) 3(80) 4(95) 5(110) 6(125) 7(140) 8(160)
Admissible shaft misalignment radial angular axial Kr Kw Ka Smax - Smin Smin to Smax mm mm mm 0.10 0.11 0.13 0.15 0.18 0.21 0.24 0.27
0.10 0.11 0.13 0.15 0.18 0.21 0.24 0.27
2-4 2-4 2-4 2-4 2-4 2-4 2-4 2-5
Fig. 6.6 Angular misalignment
Fig. 6.4 N-Eupex size Speed factor Speed
Kr and Kw apply to smooth operation and an ambient temperature of -30° C to 80° C. Admissible misalignment Kr * Sn or Kw * Sn Sn = speed factor
Fig. 6.7 Axial misalignment
Kr and Kw may occur at the same time. The sum of the two misalignments must not exceed Kr or Kw.
In order to prevent accidents, the coupling must be protected against accidental contact with a protective device in accordance with DIN 31001.
6.4
Protective and control devices
The protective and control devices provided should be incorporated and connected up in accordance with the relevant instructions.
Fig. 6.5 Radial misalignment
A motor circuit breaker should be fitted. When working on live components, first remove the mains plug or switch off at the main switch and remove the fuse. Ensure that the motor cannot be started up while the work is being carried out.
6.5
Final tasks
The following final tasks should be carried out: 1. Check that the connecting flanges are airtight. 2. Check that the pump is running smoothly.
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K07V0001.ENG
7.
Start-up and Shut-down
7.1
Safety measures
Electrical connections must be made in accordance with the regulations of the local electricity company and the ELexV specifications. The German Chemistry Society’s guideline for hazardous locations must also be observed. This work must only be carried out by authorised personnel.
The motor may be switched on briefly in order to check the direction of rotation. If the direction of rotation is incorrect, the pump may be damaged. Never allow the pump to run against the prescribed direction of rotation. Only check the direction of rotation when the pump is full.
7.3
Start-up
7.3.1
Switching on
Switch on the motor. Fill the pump in accordance with the instructions, in order to avoid any risk of damage. When using hot media, fill the pump slowly in order to prevent distortion or thermal shocks. When using explosive, poisonous, hot or caustic media, ensure that they cannot endanger life or the environment. Adjust the flow at a constant pump speed and only on the discharge side. The control device on the inlet or supply side must always be fully open during operation.
7.2
Preparations for start-up
7.2.1
Filling the pump
Completely fill the pump with the medium to be pumped. Vent the pump at the flanges via the connection auxiliaries. This only needs doing once and, if necessary, can be carried out before the pipe is connected. The next time the pump is started up, it will prime itself automatically. Check the pump shaft to ensure that it is running smoothly. Check that all the connection auxiliaries are ready for operation. Open all the shut-off devices in the inlet and discharge pipes. When pumping media at temperatures > 100° C, the pump (body of the pump) should be warmed before start-up, ideally by filling it with the hot medium and allowing this to flow through until the body of the pump reaches roughly the same temperature as the medium (at least 10 minutes).
Never (even briefly) start or operate the pump when the discharge side is closed. Do not switch the pump on until the shut-off device is open. The slide valves in the inlet pipe must also be open. If a bypass pipe is fitted, it must be closed during inlet operation. During supply operation, it may remain open. After running the unit up to the nominal speed (see rating plate), adjust the pump head by slowly closing the valve on the discharge side. The priming time depends on the length of the inlet pipe and it will take a few seconds the first time the pump is used. If a foot valve or non-return valve is used in the inlet pipe, the pump will start to work as soon as it is switched on.
7.3.2
Setting the pumping capacity values
Once normal pumping has started, the flow can be adjusted. The operational data for the pump is given on the rating plate and in the data sheet. The pump head required should be monitored on the manometer display and, if it is not correct, it should be adjusted on the discharge side. Never run the pump with the discharge side closed, even during operation. If there is a possibility that the pressure in the pump’s cross-section at the discharge side could rise to an inadmissible level due to a malfunction during operation, suitable safety measures (e.g. fitting a safety valve) should be incorporated into the system.
Under no circumstances must the pump be allowed to run dry, since overheating could damage the pump components.
7.3.3
7.2.2
Safety measures (e.g. an overflow valve) should be incorporated into the system to ensure that the working pressure is not exceeded during operation on account of a malfunction.
Driving motor
The electrical connection work must be carried out by a qualified electrician, following the VDE and local regulations, particularly the protective measures. Check the operating voltage and speed of the motor. At 50 Hz, the speed should be 1450 rpm and at 60 Hz, it should be 1750 rpm. A motor circuitbreaker should be fitted.
7.2.3
Bearings
The bearings are adequately greased at the factory and are ready for operation.
7.2.4
Checking the direction of rotation
The direction of rotation of the motor must be the same as the rotation arrow on the pump. These arrows are marked on the pump. 02.10.95
Maintaining a minimum flow
In order to prevent damage to the pump, never run it against a closed shut-off valve in the discharge pipe.
The minimum flow is shown on the pump’s output curve (smallest proven Q value).
7.3.4
Temperature
Sudden changes in temperature (thermal shocks) should be avoided.
7.3.5
Liquids with a high specific gravity
If the specific gravity of the liquid pumped is greater than that specified in the order data (i.e. greater than the specific gravity on which the design of the pump was based), the performance of the pump will decrease, while the power consumption will increase. Ensure that the motor is not overloaded.
K07V0001.ENG
7.3.6
Higher flow rates
If the flow is greater than that specified in the order and design data, ensure that the available inlet height is still sufficient (Condition: NPSHavail > NPSHreq); otherwise, cavitation could occur, with damaging consequences . If the pump is used as a boiler feed pump, ensure that the pump is not used at a lower working pressure than the intended pressure. If the feed boiler is occasionally run at a lower working pressure, then the pump must be restricted to the normal working pressure of the boiler by means of a manual shut-off valve on the discharge side and a manometer connected to the discharge socket on the pump casing.
7.3.7
Switching frequency
The pump must not be switched on and off more than 10 times per hour.
7.4
Shut-down and restart
7.4.1
Switching off
The valves on the discharge and inlet sides must not be closed before the pump is stopped. Switch off the motor. Ensure that the pump runs down evenly. If non-return valves have been fitted, the shut-off devices may not close. For long stoppages and in the event of excess (feed) pressure on the inlet side, the shut-off valve on the inlet side should be closed. The auxiliary devices (sealing liquid, etc.) should be switched off. In the case of pumps in which the liquid is under vacuum, it is important to check before starting up again whether there is still enough liquid in the pump. The pump should be topped up if necessary. If the pump remains pressurised and hot, even when shut down, all the available sealing pipes should be opened. The sealing devices must remain switched on if there is a risk of taking in air (when the pump is supplied from vacuum installations or if pumps are operated in parallel with a common intake pipe). If there is a risk of frost, completely empty the pump and pipes.
7.4.2
Restart
Check that the pump shaft has stopped. If the non-return valve in the discharge pipe is not airtight, backflow of the pumped liquid may cause the pump shaft to rotate backwards. The pump must not be switched on if the pump shaft is rotating backwards, since this could result in damage to the pump.
7.5
Precautions in the event of long stoppages
If pumps are stored for long periods before installation, they should be protected against moisture and dirt (e.g. by wrapping them in oiled paper or plastic film). For other measures: see Section 3.7 Longterm storage and monitoring the preservation. If the pumps are stored, the inlet and discharge pipe sockets and all other intake and outlet sockets must immediately be closed off with blanking flanges or plugs. During storage, the pump should be rotated at least once a month (do not switch on since it will be running dry). The position of parts such as the shaft and ball bearings should be moved each time. If necessary, they can be released by lightly tapping the shaft in the axial direction. They must be replaced after no more than 4 years, since the grease will be unusable on account of ageing.
02.10.95
For long stoppages, the pump should be filled with a suitable preservative agent. If there is a risk of frost, the pump, sealing circuit, etc, should be protected against freezing or drained and preserved.
K08V0015.eng
8.
Maintenance
Stuffing boxes may only be tightened so much that a small leakage of approx. 60 drops per minute still escapes (stuffing box lubrication!).
8.1
Safety measures
Packings that run dry do harden, overheat and destroy the shaft. After prolonged operation and frequent re-tightening of the packing rings, a further packing ring may be inserted. A fitting of a complete set of new packing rings is recommended after approximately 4.000 to 5.000 hours of operation and deformation of the rings upwards 25%.
When carrying out maintenance and repair work, the information given in Section 2. Safety must be followed. The service life will be prolonged if monitoring and maintenance work is carried out regularly on the pump and drive.
8.2
General monitoring
The pump must never be operated dry or with an interruption in the flow. Check the liquid level in the inlet and feed tanks.
Never allow the flow to fall below the minimum or exceed the maximum level.
Monitor the speed and pump head.
Do not overload the drive motor.
The pumps and units should always run quietly and without vibration. All valves, filters, etc, on the inlet side should be kept completely open.
Check the pressure and temperature monitoring devices and the flow measuring devices.
Any standby pumps fitted should be brought into service once a week by switching on and off again.
8.3
Maintenance of components
8.3.1
Bearings and lubrication
The external roller bearings are greased for life. There is no need to lubricate the closed bearings. The temperature of the bearings must not exceed 80° C. If the pump is operating correctly, the bearings should be replaced after approximately 10,000 operating hours. The internal carbon sliding bearings should also be replaced after this period of operation. If excess temperatures are identified, this indicates damage to the bearings, and the deep-groove ball bearings should be replaced as soon as possible (see Section 9. Servicing ).
8.3.2
Flexible coupling
The condition of the flexible elements in the coupling should be checked at regular intervals. Note: Replace any worn flexible elements. The distance between the two halves of the coupling should be checked for the first time after approximately 1,000 operating hours (see Section 6.3.6 Checking the flexible coupling ). The rubber coupling blocks in the jaw clutch couplings should be checked. If there is significant wear, it must be assumed that the motor is not flush with the pump or that the distance between the two halves of the coupling has changed. This will result in damage to the pump’s bearings.
8.3.3
Drive
See the operating instructions provided by the drive manufacturer.
8.3.4
Stuffing box packings
Stuffing box packings require permanent m aintenance. To increase the service life of the stuffing box packing, it is necessary to check and adjust the packing thoroughly during the first hours of operation. The stuffing box packing must have a small leakage during operation. To prevent a dry-run, the stuffing box seat resp. screwed nut should be loosened.
02.10.95
It is strictly forbidden to re-pack the pump during operation or under pressure, due to the connected danger of accident therewith.
8.3.5
Mechanical seals
Mechanical seals require no maintenance, but will only remain leakfree if looked after. During operation, ensure that the mechanical seals never run dry and the conditions of use are within the limits f or use of the selected mechanical seal. A leak of approximately 2.5 cm³ per hour is admissible. If leaks occur at the mechanical seal, the seal cannot be tightened. We recommend dismantling and checking the mechanical seal, the shaft and the adjacent sealing elements. Since the service life of mechanical seals cannot normally be estimated, we recommend keeping a stock of spare seals.
K09v0000.eng
9.
9.3
Servicing, disassembly and reassembly
9.1
Repairs to motors
Electrical repairs may only be carried out by a qualified electrician.
Safety regulations
9.4 For repairs carried out by your own personnel or by our specialist mechanics, ensure that the pump has been completely drained and cleaned. This applies in particular to pumps being sent to our factory or to one of our authorised service partners for repair.
Disassembly
The relative positions of the individual parts of the casing should be marked before disassembly (e.g. with a chalk line) so that they can be reassembled in the correct position.
In order to protect our employees and the environment, we cannot accept for repair any pumps which are still full of pumping medium. If pumps containing pumping medium are sent to us, we will invoice the customer/owner for the costs of environmentally-friendly disposal. If pumps which have been operated with hazardous materials and/or media which represent a danger to the environment are sent for repair, the customer/owner must notify his own or our repair personnel on site or the staff at our factory or authorised service partner when the pump is returned for repair. In this case, the request for a customer service mechanic must be accompanied by details of the pumped liquid, for example in the form of a DIN safety data sheet. For all work on site, your own staff and our mechanics must be told about the hazards which might arise in connection with the repairs.. These instructions describe the most important disassembly and assembly work. The assembly steps described in the individual sections must be followed rigorously.
9.2
Notes before disassembly
During the guarantee period, the pump may only be opened by us or by one of our authorised service partners.
Outside the guarantee period, the pump should only be disassembled and reassembled by experienced personnel.
Before commencing disassembly, the unit must be secured to prevent it being switched on accidentally.
The pump housing must be depressurised and drained.
All valves in the inlet, feed and discharge pipes must be closed.
All temperature.
parts
must
have
returned
to
the
ambient
For repairs, the motor, baseplate and pipes should be should be removed from the pump.
02.10.95
Detailed instructions for disassembly and reassembly are available on request. Please refer to: see last page.
K10V0001.ENG
10.
Faults; causes and correction
10.1
Safety regulations
Troubleshooting must only be carried out by experienced technical personnel. In the event of a fault, the pump must be switched off as quickly as possible.
10.2
Faults and how to correct them
Faults
Cause
To correct
Pumping capacity too low
Counter-pressure too high.
Reset the operating point.
Suction lift too high or inlet height too low.
Check the liquid levels, open the shut-off devices on the inlet side.
Filter clogged.
Clean the filter and dirt trap on the inlet side.
NPSH not observed.
Sealing gap too large due to wear.
Replace the worn pump parts.
Wrong direction of rotation or speed.
Connect the motor up again.
Casing or inlet pipe not airtight.
Replace the casing seal. Check the flanged connections.
Pump not priming
Pump leaking
Temperature rise in the pump
02.10.95
Inlet pipe or shaft seal on the inlet side not Replace the casing seal. Check the flanged airtight. connections.
Suction lift too great.
Gaps between impeller and stage too large Replace the worn pump parts. due to wear.
Wrong direction of rotation.
Connect the motor up again.
Amount of liquid in the pum p too low.
Top the pum p up again
Inlet or discharge valve closed.
Open all the valves
Wrong pipe connection.
Connect the pump up again.
Wrong electrical connection.
Connect the motor up again.
NPSH not observed.
Clean the filter and dirt trap on the inlet side.
Stopper not removed.
Remove the stopper.
Casing screwed connection not airtight.
Check the tightening torque of the casing screws.
Seals defective.
Replace the seals.
Pum p or pipe not com pletely full.
Vent and fill t he pum p, inlet and feed pipes.
Suction lift too high or inlet height too low.
Check the liquid levels, open the shut-off devices on the inlet side.
Pump running dry.
Clean the filter and dirt trap on the inlet side.
Check the liquid levels.
K10V0001.ENG
Faults
Causes
Pump not running smoothly or is noisy
Pump or pipe not filled completely.
Suction lift too high or inlet height too low Check the liquid levels, open the shut-off devices (cavitation). on the inlet side.
Pump has fallen below Q-min..
Pump not standing evenly on the sub-floor or Check the pump installation. is distorted by tension.
Foreign bodies in the pump.
Dismantle and clean the pump.
Foreign bodies in the pump.
Dismantle the pump and replace the damaged parts.
Valve closed in the discharge pipe.
Open the shut-off devices.
Admissible pumping conditions not observed.
Note the pumping conditions specified in the data sheet.
Increase in output greater than the set upper Check the motor circuit-breaker and electrical threshold value. connections.
Increased friction in the pump.
Motor circuit-breaker tripping
02.10.95
To correct Vent and fill the pump, inlet and feed pipes.
Clean the filter and dirt trap on the inlet side.
Check whether:
the pump is blocked by impurities.
the stopper is too tight.
the shaft is mounted correctly.
K11V0001.ENG
11.
Associated documents
11.1
Impeller gap dimensions
Pump, material version 10, 12, 22 with gasket (tmax = 120° C) Pump series Impeller width Depth on the Thickness of the discharge side seal 100/110 10 - 0.02 9.98 + 0.02 0.15 + 0.02 210/220/330 10 - 0.02 9.98 + 0.02 0.15 + 0.02 440 14 - 0.02 13.98 + 0.02 0.17 + 0.02 550 19 - 0.04 19.01 + 0.04 0.17 + 0.02 660 22 - 0.04 22.01 + 0.04 0.17 + 0.05 Pump, material version 32 with PTFE O-ring (tmax = 120° C) Pump series Impeller width Depth on the Thickness of the discharge side seal 100/110 10 - 0.02 10.15 + 0.02 0.03 210/220/330 10 - 0.02 10.15 + 0.02 0.03 440 14 - 0.02 14.16 + 0.02 0.03 550 19 - 0.04 19.18 + 0.04 0.03 660 22 - 0.04 22.18 + 0.04 0.03 Pump, material version 10, 12, 22 with gasket, T-shaped (tmax = 140° C) Pump series Impeller width Depth on the Thickness of the discharge side seal 100/110 10 - 0.02 10.04 + 0.02 0.15 + 0.02 210/220/330 10 - 0.02 10.07 + 0.02 0.15 + 0.02 440 14 - 0.02 14.07 + 0.02 0.17 + 0.02 550 19 - 0.04 19.14 + 0.04 0.17 + 0.02 660 22 - 0.04 22.16 + 0.04 0.17 + 0.05 Pump, material version 32 with PTFE-O-ring, T-shaped (tmax = 140° C) Pump series Impeller width Depth on the Thickness of the discharge side seal 100/110 10 - 0.02 10.21 + 0.02 0.03 210/220/330 10 - 0.02 10.24 + 0.02 0.03 440 14 - 0.02 14.25 + 0.02 0.03 550 19 - 0.04 19.31 + 0.04 0.03 660 22 - 0.04 22.33 + 0.04 0.03
Overall gap
Gap on each side
0.13 0.13 0.15 0.18 0.18
0.065 0.065 0.075 0.09 0.09
+ 0.06 + 0.06 + 0.06 + 0.1 + 0.13
+ 0.03 + 0.03 + 0.03 + 0.05 + 0.065
Overall gap
Gap on each side
0.18 0.18 0.19 0.21 0.21
0.09 0.09 0.095 0.105 0.105
+ 0.04 + 0.04 + 0.04 + 0.08 + 0.08
+ 0.02 + 0.02 + 0.02 + 0.04 + 0.04
Overall gap
Gap on each side
0.19 0.22 0.24 0.31 0.33
0.095 0.11 0.12 0.155 0.165
+ 0.06 + 0.06 + 0.06 + 0.1 + 0.13
+ 0.03 + 0.03 + 0.03 + 0.05 + 0.065
Overall gap
Gap on each side
0.24 0.27 0.28 0.34 0.36
0.12 0.135 0.14 0.17 0.18
+ 0.04 + 0.04 + 0.04 + 0.08 + 0.08
+ 0.02 + 0.02 + 0.02 + 0.04 + 0.04
The appendix contains: 11.2
Sectional drawing of the pump
11.3
Sectional drawing of the shaft seal
11.4
Data sheet
The technical data for the pump is given in the data sheet. The dimensions are given in a table of measurements which will be sent to you upon request.
12.
Identification
Each pump has a company rating plate conforming to DIN 24 299. as shown in fig. 12.1.
Fig. 12.1
02.10.95
K11V0116.eng
11.2
Sectional drawing of the pump
VKO...WW
VKO...W
VKR...WW
02.10.95
K11V0116.eng
SOB...W
SRB...WW
SOV...W/SRV...W singlestage
02.10.95
SOV...W/SRV...W multistage
K11V0215.eng
11.3
Sectional drawing of the shaft seal
Mechanical seal configuration
Stuffing box configuration
Part no.
Designation
Part no.
Designation
1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 17 18 21 22 23 24
Discharge casing Suction casing Suction cover Discharge stage casing Suction stage casing Impeller Shaft Bearing housing Housing bracket Bearing housing Antifriction bearing Bearing cover Bearing end cover Spacer ring Bearing bush, long Bearing bush, short Sockethead cap screw Thrower Gasket, wide Gasket, narrow Packing ring
26 27 28 29 30 31 33 34 35 36 41 42 43 51 52 53 61 62 63 64 65
Stuffing box Screwed nut Woodruff key Disc Shaft nut Plug Connection bolt with nut Crossover pipe Screwed connection Lantern ring Coupling half, pumpside Coupling half, motorside Coupling insert Counter flange Flange seal Hexagon head screw Mechanical seal Stationary seal Gasket Circlip Seal locating ring
02.10.95
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 10
Service Type: Description
Hot water circulatin um UP 25-72/180 Centrifugal pump for pipe mounting
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61353
70 1030 2,00 6,00 6,50 0,50 0,10 0,20 3450
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Polyethersulfon
Rolling contact grease S DN G 1 1/2" G 1 1/2"
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : IM V18, IP 55, ISO B : DOL : 440 / 60 : 0,20 : 0,31 : 3,00
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
PTC : SPM : no Space heater : no
Weights
3,00
/
Total
(kg)
: 3,00
16.02.2005
Grundfos UP UPS INSTRUCTIONS UPD, UPSD
GRUNDFOS
UP, UPS, UPD, UPSD
1.0 MPa (10 bar)
Hmax 0.7...12 (m)
3
t
Type t
t min.: +2˚C t min.: -25˚C t min.: -25˚C t max.: +110˚C t max.: +95˚C t max.: +110˚
Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx OK
OK
OK 4
OK
OK
t1 t2
> t t1 = 2 0 1 1 F T
t1˚C
2
40
60
80
90
100
105
110
Max. t2˚C
0
40
40
40
40
40
40
40 5
OK
OK
OK
OK
(OK)
UPSD OK
6
(OK)
(OK)
OK
(OK)
(OK)
7
1
2 8
1
2 1
2
3
9
1
2
10
2
11
12
13
14
15
www.grundfos.com
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 11
Service Type: Description
Com osite boiler feed water um no.1 SFH 334 WW G Horizontal side channel pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61354
75 1000 6,00 12,00 12,00 5,50 6,30 1760 2,40
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Brass Stainless steel Rolling contact grease Mechanical seal C-ceramic EPDM DN 32 32
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump
Power supply Power Rated current Starting current
CSM 132S-4 IM B3, IP 55, ISO B DOL 440 / 60 6,60 11,30 90,60
PTC : SPM : no Space heater : no
Weights
52,00
/
62,00
Total
(kg)
: 114,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 11
Service Type: Description
Com osite boiler feed water um no.2 SFH 334 WW G Horizontal side channel pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61355
75 1000 6,00 12,00 12,00 5,50 6,30 1760 2,40
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Brass Stainless steel Rolling contact grease Mechanical seal C-ceramic EPDM DN 32 32
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump
Power supply Power Rated current Starting current
CSM 132S-4 IM B3, IP 55, ISO B DOL 440 / 60 6,60 11,30 90,60
PTC : SPM : no Space heater : no
Weights
52,00
/
62,00
Total
(kg)
: 114,00
16.02.2005
Operating instructions SFH 110-550 WW Ident. no.: Serial no.: Contents 0. Brief instructions 1. General Application 2. Safety 3. Transportation and temporary storage Preservation 4. Description Structural design 5. Planning the system Pipes, safety equipment 6. Installing the pump Safety measures 7. Start-up / shut-down 8. Maintenance 9. Servicing, disassembly, reassembly Spare parts, standby pumps 10. Faults; causes and correction 11. Associated documents 12. Pump identification
18.09.03
This pump may only be installed and brought into service by trained personnel, who must precisely follow these operating instructions and the applicable legal requirements. If these operating instructions are not followed: you may be putting yourself or your colleagues at risk, the pump or the pump unit may be damaged, and the manufacturer will not be liable for any resulting damage! When working on the pump or pump unit, please remember that you are responsible for the safety of your colleagues!
These operating instructions conform to the provisions of EN292 part 2, sub-section 5.5 and the safety regulation EN809.
K00V0001.ENG
0.
Brief instructions on starting up a pump unit supplied complete
The pumped liquids must not have a tendency to crystallise out and must contain no potentially abrasive solids (see section 1.1 Application).
Remove the protective caps from the pipe sockets before connecting the pipes.
If the pump has been preserved, drain off the preservative agent (dispose of correctly) and clean the pump.
Align the pump or pump unit on the foundation and fix in place.
Clean the pipes.
Note the directions of flow and rotation (see arrows on the pump).
Fill the pump with liquid (the pump must have been thoroughly vented).
Open all the shut-off devices in the inlet and discharge pipes.
Check that the coupling guard is fitted and all the safety equipment is ready for operation.
Fit a motor circuit-breaker. The electrical connection work may only be carried out by a qualified electrician. Check the voltage, speed and direction of rotation.
Turn the unit manually and ensure that it is running smoothly and evenly.
Switch on the motor.
Once it has run up to operational speed, check the operating pressure on the manometer and set the operating point by restricting the pressure on the discharge side, if necessary.
Do not allow the flow to fall below the minimum value.
The pump must be constantly supplied with fluid. It must never be allowed to run dry.
Never touch a pump while it is running - it may be hot/cold.
The power consumption increases as the pump head rises and the amount of liquid pumped decreases.
The pump must never be started up or operated when the inlet and/or discharge pipe is closed.
During assembly or operation, the pipes must not transmit stresses to the pump.
The safety instructions specified under point 2-ff must be followed.
02.10.95
K01V0001.ENG
1.
General
1.1
Application
1.3
Characteristics of side channel pumps
This is a self-priming side channel pump. It is suitable for pumping pure, cloudy and gaseous liquids containing no abrasives (size not larger than 0,1 mm). In design, it corresponds to a multistage ring section pump. The use of standardised components for several pump series and sizes makes it economical to keep a stock of standby parts and to purchase spare parts. The pump is driven by an electric motor. The pump should be used only under the operating conditions specified by the customer and confirmed by the supplier. The correct and intended application is specified in the data sheet supplied with the pump, a copy of which is shown in the appendix.
Fig. 1.1
The pump must only be used for the application specified in the data sheet. Otherwise, it may endanger both people and the environment. Do not allow the specific gravity to fall below or exceed the value specified in the data sheet, since this could result in damage to the pump.
Systems in which a failure or malfunction could lead to injury or damage should be fitted with alarm systems and/or standby units and should be checked at regular intervals to ensure that they are in good working order.
Fig. 1.2
Units which are directly or indirectly linked to drinking water supplies should be thoroughly cleaned before installation and start-up to remove all impurities.
Never touch a pump while it is in use - it may be hot. The data relating to speed, pressure and temperature contained in the data sheet are values at which correct functioning of the pump is guaranteed. It is essential to adhere to these values. Fig. 1.3
Requirements: If the outlet side of a pump is closed while the pump is running, the temperature of the liquid in the pump may rise to a dangerous degree. Dangers may arise from overpressure and subsequent failure of part of the pump or pipework. Particular dangers arise if the liquid being pumped is flammable, as it will be more easily ignited at increased temperatures. Explosions may occur if the liquid is chemically unstable when overheated. These dangers are commonly prevented by providing a liquid return loop incorporating a pressure relief valve. It is also important not to fall below the specified inlet pressures (system pressures). If the order confirmation does not specify any pressures and/or temperatures, then the limit pressures and temperatures specified in the brochure apply, provided that no further restrictions are imposed by the type of shaft seal used.
1.2
Testing
All our pumps undergo extensive testing on the test bench before they leave the factory. Only pumps which are running perfectly and achieve the promised performance levels, taking account of the specified tolerances, are allowed to leave the factory. If these operating instructions are followed, we guarantee fault-free operation and full pumping capacity. Test pressure = 1.5 x pump operating pressure 02.10.95
1. Start up with the valves open. 2. Never work with the discharge pipe closed. 3. Only work within the range from Qmin to Qmax.
1.4
Guarantee
Our liability for defects in the goods supplied is set out in our delivery conditions. We accept no liability for damage caused by not following the operating instructions or not observing the conditions for use. If the operational conditions subsequently change (e.g. different liquid to be pumped, different speed, viscosity, temperature or inlet conditions), then we must be given an opportunity to investigate the individual case and, if necessary, to confirm whether the pump is suitable for the intended purpose. Unless special arrangements are made, pumps supplied by us may only be opened or modified by us or by our authorised service partners during the guarantee period. Otherwise, we will not be liable for any defects.
K01V0001.ENG
1.5
Noise level
Depending on the pump size, the noise from our pumps falls within the range from 60 to 72 dB(A).
Expected noise values of side channel pumps at a speed of n=1450 1/min 75 ] ) A ( b d [
70
A
L l e v e l
65
e r u s s e r p e s i o N
60
55
50
45 1
10
Power P [kW]
Fig. 1.4
However, the pump is not necessarily the only possible source of irritating noise. Other possible sources of noise are:
the drive
the coupling, which may be been fitted incorrectly
other devices in the same area (e.g. heating system)
the water pipes, cocks or valves. Flowing water always causes noise (e.g. water hammer). However, such noise may be reduced by suitable measures, so that it no longer causes a disturbance.
The water flow speed should be kept as low as possible. Large pipes, pressure reducers and other devices are particularly suitable for reducing the flow speed. If the pump is the major source of noise, the noise can be deadened by the following measures: 1. Place the pump on rubber buffers. 2. Insert a rubber connector into the inlet and discharge pipes, between the pump and the pipes. 3. Do not allow pipes to come into direct contact with walls, ceilings or floors. 4. If necessary, enclose the pump (but not the motor) in a soundproof enclosure.
02.10.95
K02V0001.ENG
2.
2.4
Safety
These operating instructions contain fundamental information which must be followed during installation, operation and maintenance. Consequently, before assembly and start-up, these operating instructions must be read by the mechanic and the competent technical personnel / operators, and must be available at all times in the vicinity of the machine / system. In addition to the safety instructions given in this section, the other special safety instructions (e.g. for private use) given in other sections must also be followed. Local safety regulations will not be superseded by these operating instructions.
2.1
Identification of instructions in these operating instructions
If certain safety instructions in these operating instructions are not followed, there could be a risk to personal safety. These instructions are identified by the general hazard symbol:
Safety symbol according to ISO 3864-B.3.1 In the case of warnings about electrical voltage, the safety instructions are identified by:
Safety symbol according to ISO 3864-B.3.6 For safety instructions which, if they are not followed, could endanger the machine and its functioning, the word WARNING is inserted. Instructions attached to the machine, such as the direction of rotation arrows or liquid connection markers, must be followed and must be fully legible at all times.
2.2
Personnel qualifications and training
The operating, maintenance, inspection and assembly personnel must have the appropriate qualifications for this work. The area of responsibility, competence and staff supervision must be precisely stipulated by the owner. If none of the personnel has the necessary experience or knowledge, then they must be given training and instruction. If necessary, this can be provided by the manufacturer/supplier at the machine owner’s request. The machine owner should also ensure that the content of the operating instructions is fully understood by his employees.
2.3
Risks if the safety instructions are not observed
Failure to observe the safety instructions can endanger people, the environment and the machine. Any claims for damages may be invalidated if the safety instructions are not followed. Failuire to observe the safety instructions can, for example, lead to the following risks:
Failure of important machine/system functions
Failure of prescribed maintenance and repair methods
Lives may be put at risk by electrical, mechanical and chemical hazards.
Risk to the environment caused by the leaking of hazardous materials.
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Safe working practices
The safety instructions given in these operating instructions, the applicable national accident prevention regulations and the owner’s internal working, operational and safety regulations should be followed.
2.5
Safety instructions for the owner / operator
If hot or cold machine parts represent a potential risk, these parts must be protected on site against accidental contact.
Protective devices on moving parts to prevent accidental contact (e.g. coupling guard) must not be removed while the machine is in use.
Leaks (e.g. from the shaft seal) of hazardous (e.g. explosive, poisonous, hot) liquids must be eliminated so that they do not endanger life or the environment. The legal regulations must be observed.
Measures should be taken to prevent the risk of electric shock (for further information on this subject, see the VDE regulations and those of t he local electricity company, for example).
2.6
Safety instructions for maintenance, inspection and assembly work
The owner must ensure that all maintenance, inspection and assembly work is carried out by authorised and qualified technical staff who have read and understood the operating instructions. Work must only be carried out when the machine is shut down. The procedure for shutting down the machine described in the operating instructions MUST be followed. Pumps or pump units containing media which are a potential hazard to health must be decontaminated. Pumps sent to us for repair should be cleaned beforehand so that they do not represent a hazard to the health of our employees. As soon as the work has ended, all safety and protective devices must be replaced or brought into service once more. Sections 7.1, 7.3 and 7.4.2 must be followed before starting up the machine again.
2.7
Conversion and production of spare parts by the owner
The machine may not be converted or modified without the manufacturer’s prior approval. The use of original spare parts and accessories authorised by the manufacturer ensure operational safety. The use of other parts may invalidate our liability for any resulting damage.
2.8
Inadmissible operating methods
The operational safety of the machine can only be guaranteed if it is used in the manner intended, as described in Section 1 General of these operating instructions. The limit values specified in the data sheet must not be exceeded under any circumstances.
K03V0001.ENG
3.
3.1
Transportation and temporary storage Safety measures
Never stand beneath a suspended load. Always keep a safe distance from the load while it is being moved. Only use the prescribed lifting tools and ensure that they are in perfect condition. Adjust the length of the lifting devices so that the pump or unit is suspended horizontally. Do not remove any documents that are attached to the pump. Always handle the pump with care.
3.6
If we have applied a preservative agent at the factory, this will be brought to the user’s attention: 1. On the plate attached to the pump 2. By way of a notice on the delivery note and invoice. The preservative agent will last for 6 months. Please note that all pumps made from cast iron or spheroidal graphite cast iron that are brought into service (even for a trial run) must be corrosion protected when they are shut down again. A preservative agent should be applied both internally and externally, following the instructions in sections 3.6.1 + 3.6.2.
3.6.1
Packaging
The symbols on the packaging should be observed. The inlet and discharge sides of the pump must be closed off with caps during transportation and storage. When installing the pump unit, the flange caps should be removed.
3.3
Unpacking
Before unpacking, carry out a visual inspection of the packaging. If any damage has occurred during transportation, note the extent of the damage on the receipt or delivery note. Any claims should be made immediately to the carrier company or carriage insurance company.
3.4
Temporary storage
If the pump or unit is not installed immediately upon delivery, the machine must be st ored frost-free in a dry and vibration-free area.
3.5
Preservative agent
The preservative agent specified below may be used for both external and internal preservation.
3.2
Preservation
Preservative-agent: FINA BIOHYDRAN TMP 32, Total Fina Deutschland GmbH, 40217 Düsseldorf
For external preservation, all blank and unpainted parts, such as shaft ends, flange surfaces, are preserved. Apply the preservative agent using a brush or spray gun. For internal preservation, the inside of the casing, shaft, impellers and the shaft seal are preserved. Introduce the preservative agent by filling the pump. During the filling operation, turn the shaft slowly in the direction of rotation. Continue filling until the preservative agent reaches the sealing strips of the inlet and discharge flanges. Then, close the pressure and inlet sides using a blanking flange. NOTE: The specified preservative agent should be regarded as a recommendation. Preservative agents with equivalent preservative characteristics from other mineral oil manufacturers may also be used. According to the preservative agent manufacturer’s specifications, the preservative agent will last for 6 months. The effective ingredients of the preservative agent also provide adequate corrosion protection in areas with increased atmospheric humidity (at sea, tropical climate).
Transportation
The pump must be transported correctly. Fig. 3.1 shows the correct handling methods.
When moving the pump unit using a crane, the crane and slings must be of a suitable size. The slings must not be attached to the motor eyes.
3.6.2
Removal and disposal of the preservative agent
Before start-up, the preservative agent must be removed. The preservative agent introduced for internal preservation must be drained off.
Preservative agents must be disposed of correctly. The pump must be cleaned completely. This is of particular importance for pumps which are used in the food or drinking water supply industries. A suitable solvent which is compatible with the pumped liquid (and with foodstuffs) may be used as the cleaning agent for removing the internal and external preservation.
3.7 Fig. 3.1 Pump with motor on a base plate
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Long-term storage and monitoring the preservation
If the pump is stored for long periods, the owner must check the preservation at regular intervals. The fill level of the pump should be checked every 6 months. If necessary, the preservative agent is topped up to the sealing strip on the discharge flange resp. to be renewed.
K04V0001.ENG
4. 4.1
Description
4.10
Structural design
A list of the accessories supplied with the pump is given in the data sheet. The associated operating and installation instructions are also given in the appendix.
Self-priming ring section pump which acts as a side channel pump. The capacity of the side channel pump is dependent, in particular, on the gap between the impeller and stage casing (0.15 to 0.17 mm). Given the narrow clearances, the pump is not suitable for pumping media containing solids (in certain cases, a filter should be provided on the inlet side).
4.2
Casing
The joints between the casing and sides on the inlet and discharge sides run transversely. The casing and casing parts are sealed with respect to one another by means of gaskets.
4.3
Pipe sockets / flanges / dimensions
See data sheet.
4.4
Connecting auxiliaries
In the discharge casing, the pumps contain:
1 screw-in plug for connecting a manometer.
1 screw-in plug for draining off the liquid.
In the inlet casing, the pumps contain:
1 screw-in plug for connecting a mano / vacuummeter.
1 screw-in plug for draining off the liquid (complete drainage is not possible).
4.5
Impellers
These are open, star-shaped wheels which compensate for axial thrust by means of relief holes.
4.6
Shaft
The pump is equipped with a particularly rigid shaft, which ensures fault-free operation under all load phases.
4.7
Bearings and seals
See data sheet.
4.8
Drive
The pumps are driven by an electric motor. In most cases the motors used are fan-cooled three-phase AC squirrel cage motors, model B3 or B14, type of protection IP44/54 to IEC standards, insulation class B, motor winding for 380 V or 660 V, 50 or 60 Hz. Explosion-proof motors and other design versions may also be used.
4.9
Coupling and protective devices to prevent accidental contact
For our pumps, we use a flexible elastic coupling made by Flender, type N-Eupex, model B.
In order to prevent accidents, the coupling must be secured with a protective device in accordance with DIN 31001 to prevent accidental contact. When pumping explosive materials, the protective device must be made from a material which does not produce sparks (e.g.: brass).
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Accessories
If you wish to fit other accessories to the pump or pump unit, please notify the manufacturer of the accessories you plan to use.
K05V0001.ENG
5.
Planning the system
5.1
Piping system Note the flow arrows on the pump’s pipe
sockets. Select the nominal diameters of the pipes so that they correspond to the nominal diameters of the pipe sockets (see data sheet). Do not forget to clean the pipes before they are installed. Support the pipes to ensure that no stresses are transferred to the pump (which could result in broken pump components). Avoid sudden changes in cross-section and direction. Compensate for differences in nominal diameter using eccentric transitions, thus preventing air pockets forming in the pipe.
Do not dispose of corrosion protection agents in the sewage system.
5.2
Inlet pipe
In order to guarantee cavitation-free operation, the instructions in Section 5.4 Inlet conditions must be followed. The inlet pipe can be laid in any form. It may pass over the pump since the liquid can also be sucked over the top. The cross-section of the inlet pipe must not be smaller than the pump’s suction pipe socket. Every effort should be made to achieve a flow speed of 1 m/sec in the suction pipe. Under particularly difficult pumping conditions, we also recommend providing a calming section on the suction side, upstream of the entry to the pump. The length of this calming section should be 10 x the pipe diameter. In suction mode, the suction strainer should be at least 0.2 m below the lowest level of the liquid (see fig. 5.1).
Upstream of the pump’s inlet pipe socket, install a calming section with the same diameter as the nominal diameter of the inlet socket and ten times as long as the inlet socket diameter. This will prevent cavitation. The flow speed in the inlet and feed pipes should not exceed 1 m/sec.
5.1.1
Nominal diameter
The size of the pipes must guarantee perfect flow conditions in the pump and thus have no detrimental effect on the functioning of the pump. Every effort should be made to ensure that the flow speed in the inlet and discharge pipes does not exceed 1 m/sec. Particular attention should be paid to the air-tightness of the inlet pipe and observing the NPSH values.
5.1.2
Changes in cross-section and direction
The flow direction through the body of the pump is indicated by arrows on the pump casing.
Fig. 5.1 Non-return valve Suction strainer (Non-return valve)
Sudden changes in cross-section and direction and excessively sharp bends should be avoided.
5.1.3
Supporting elements and flanged connections
Ensure that all pipes sockets are stress-free. The pipes should be supported in the vicinity of the pump and screwed loosely in place to prevent distortion. After loosening the screws, the flanges should not stand at an angle or spring back and should not be under pressure on both sides. Any thermal stresses on the pipe should be kept away from the pump by suitable measures, for example by fitting compensators. Hydraulic forces should also be absorbed by suitable pipe fasteners upstream and downstream of the pump. The pump has to be decoupled from the system and environment in respect to vibrations.
5.1.4
Cleaning the pipe before installation
It is important to ensure that the pipes are completely clean when they are brought into service. They must be free of weld beads, burrs, rust, etc. Flange seals must not project inwards. The sockets should be checked to ensure that they are air-tight (see Section 3.6 Preservation ).
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In order to maintain its self-priming capacity, the pump must always be filled with the liquid to be pumped. The side channel pump is able to carry air or gases and to evacuate a suction pipe. The pumps must be filled with liquid. The suction capacity is restricted to a vacuumetric suction lift of approximately 7 m (for water at 20° C) and decreases as the wear increases. The priming time should be limited to 1 minute at most, since the priming stagnates when the medium in the pump heats up. A non-return valve should be fitted in order to avoid having to lift out the pump after switching off (see fig. 5.1). For inlet operation, ensure that the liquid level remains at least 0.5 m above the pipe socket. For supplying liquid from a tank under vacuum, we recommend installing a compensation line (CL) (see Fig. 5.2).
K05V0001.ENG
5. When running two pumps in parallel, both pumps should be allocated a separate inlet pipe (see fig. 5.3). 6. Never connect the inlet pipe vertically to the feed tanks. It should always be horizontal in order to prevent the formation of eddy currents (see fig. 5.3).
Fig. 5.3 Wrong Right Fig. 5.2 Non-return valve
5.3
Discharge pipe
A constant cross-section of the pipes is also desirable on the discharge side. For a large pump head and long discharge pipes, it is sensible to fit a gently closing non-return element on the discharge side (non-return valve) (see fig. 5.1 + 5.2).
5.4
Supply conditions (NPSH)
In order to guarantee fault-free continuous operation, the inlet and suction conditions of the system should be matched to the pumping demand (NPSH). The operating conditions are fulfilled if the system NPSH value (NPSHavail) is greater than the pump NPSH value (NPSHreq.). NPSHavail. > NPSHreq.
7. Take precautionary measures to ensure that the feed pump can never run dry. 8. In the case of extremely large pumps, fit a regulating valve in the discharge pipe. 9. In the inlet and discharge pipe, allow for the installation of compensators. In addition, provision should be made for a filter in the inlet pipe and a non-return valve in the discharge pipe (see fig.5.3). 10. Do not fit quantity-dependent control valves in the pump’s discharge pipe. 11. When designing the system, the poorest NPSH value at the lowest possible pumping pressure should be taken into account. 12. Provide pressure measuring devices on the inlet and discharge sides. 13. Design the slide values in the inlet and discharge pipes so that they cannot be unintentionally closed. 14. If the pressure differential is sm aller than that intended, the NPSH range for the feed pump will not be so good. In order to prevent damage, the pump should be restricted accordingly (see fig. 5.4).
The (NPSHreq.) for each type of pump is given in the characteristic curves. Upon request, we can send you a special leaflet on calculating the NPSH values. During inlet operation, it is important to ensure that the geodetic suction lift of 7 m (for water at 20° C) is not exceeded. Please note that, with media with low vaporisation pressures or water at a temperature greater than 20° C, the suction lift of the pump will decrease accordingly. When pumping liquids at close to boiling point, watch the NPSH value and the inlet height since this could lead to cavitation in the pump, which will damage the hydraulic system.
5.5
Notes on planning and constructing boiler installations
1. Design the feed pump with an appropriate reserve in accordance with TRD 401. 2. If there are two possible types of pump, the best option is always to use the pump with the better NPSH value. 3. The length of the inlet and discharge pipes of the boiler feed pump should be kept as short as possible, and the number of elbows and bends kept to a minimum. 4. The inlet pipe should be a nominal diameter size larger than the socket on the inlet casing. Do not make sudden reductions in the pipe diameter.
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Fig. 5.4 Pressure falling NPSH rising
5.6
Safety equipment
Speed, pressure and temperature Suitable safety measures must be taken on site to ensure that the speed, pressure and temperature cannot exceed the limit values specified in the data sheet (see DIN 24295, Point 3.4). Sealing, purging and cooling Suitable regulating and monitoring options should be provided for any purging or sealing systems which may be fitted. For the required quantities and pressures, see the description of the shaft seals (see Section 8 Maintenance). In the case of dangerous media or high temperatures, care should be taken to ensure that the pump will shut down if the sealing or purging system fails. The sealing and purging systems must always be switched on before the pump is started up. They should not be switched off until the pump has stopped completely, if this is permitted by the type of operation (see Section 7 Start-up and shut-down).
K05V0001.ENG
Minimum quantities, working range The working range specified in the characteristic curve sheets should be used and the pump should not exceed or fall below this range during operation. The left-hand limit on the characteristic curve represents the minimum quantity for the pump. Suitable measures, such as freewheel non-return valves or a by-pass line, should be provided on site in order to guarantee the minimum quantity for the pump under all operating conditions. Ensure that the transfer capacity is not exceeded. If required, we will be pleased to help you with the design of the freewheel non-return valves or by-pass line. The inlet and discharge sides of the pump should each be equipped with a mano/vacuummeter or manometer. In order to be able to maintain the pump head precisely (see rating plate), a regulating valve should be provided on the discharge side. For larger pump heads (> 20 m), long pipes, parallel operation and system counterpressure, a non-return valve (R) should be installed on the discharge side in order to prevent back-flow through the pump when the unit is switched off (see fig. 5.1 + 5.2).
5.7
Electrical connections
The power supply cable for the driving motor should be connected by a qualified electrician in accordance with the motor manufacturer’s circuit diagram. The applicable VDE regulations and the regulations of the local electricity company should be observed. All risks of electric shock should be eliminated.
5.8
Inspection
Once installation is complete, all the pipes and sockets should be tested to ensure they are airtight. The unit should be tested to ensure that it is free of blockages (It should be possible to turn the shaft assembly by hand).
The operational safety of the installation (electrical connections, coupling guards, etc.) should be checked with reference to the applicable accident prevention regulations.
5.9
Hydrostatic pressure test
When carrying out a hydrostatic pressure test on the piping systems, the pump should be excluded from the test. If the pipes cannot be pressure tested without the pump, care should be taken to ensure that no foreign bodies enter the pump. The maximum pressure that may be applied to the pump during the test is 1.3 times the design pressure of the pump . The design pressure is given in the data sheet in the appendix. In the case of pumps with a gland, the packing should be replaced after the pressure test (since it will be compressed too much and will no longer be suitable for use). When emptying the pipe after the pressure test, a preservative agent should be applied to the pump (to avoid rusting and problems during start-up). The pipes must be connected to the pump so that the reaction forces which occur on the pipes never exceed the maximum admissible forces and torques at the pipe sockets. Before start-up, the piping system and installed fittings, devices, etc must be cleaned of impurities such as weld beads, scale, etc.
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K06V0001.ENG
6.
Installing the pump
2. Tighten the pump feet and motor feet. The feet should only be hand tight.
6.1
Safety measures
6.3.6
Checking the flexible coupling
After connecting the pipes, the alignment of the coupling must be checked, and adjusted if necessary. Carefully connect the pipes in order to prevent the medium used leaking out during pumping and endangering the operators. Ensure that the inlet and feed pipes and the discharge pipe are closed off.
Ensure that all the electrical connections are switched off in order to prevent potentially fatal electric shocks.
6.2
Fig. 6.1 Aligning with a straight-edge
Assembly tools
No special tools are required for setting up and installation.
6.3
Initial installation
6.3.1
Ambient conditions
The ambient temperature may be between -20° C and +40° C. The air humidity should be as low as possible in order to prevent corrosion.
6.3.2
Sub-floor and foundation
The pump must stand on a flat, vibration-free floor or foundation. In cases of doubt, vibration-damping feet should be used.
6.3.3
Fig 6.2 Aligning with a dial test indicator
Spatial requirements
The spatial requirements of the pump unit are given in the table of dimensions. Ensure that there are no obstructions to prevent access to the shut-off and control valves and to the m easuring devices. Sufficient space should be provided for maintenance and repair work, particularly for replacing the drive motor or entire pump unit.
6.3.4
Pre-installation checks
Before incorporating the pump into the system, the following points should be checked:
Has the drive motor been switched off?
Have the inlet, feed and discharge pipes been drained and closed off?
Can the pump be easily turned by hand (by turning the impeller on the motor)?
Have all the internal company regulations been followed?
6.3.5
Installing the pump and incorporating it into the piping system
Align the pump with the pipes. The pipes should be supported so that, when the pump is connected, no twisting can occur. When tightening the screws, follow the sequence given below: 1. Tighten the flanged connections. Remove the protective caps from the connectors before connecting the pipe. 02.10.95
Fig. 6.3 Aligning with a dial test indicator
Admissible misalignment for flexible couplings (only applies to original couplings supplied by us):
K06V0001.ENG
Size
1(58) 2(68) 3(80) 4(95) 5(110) 6(125) 7(140) 8(160)
Admissible shaft misalignment radial angular axial Kr Kw Ka Smax - Smin Smin to Smax mm mm mm 0.10 0.11 0.13 0.15 0.18 0.21 0.24 0.27
0.10 0.11 0.13 0.15 0.18 0.21 0.24 0.27
2-4 2-4 2-4 2-4 2-4 2-4 2-4 2-5
Fig. 6.6 Angular misalignment
Fig. 6.4 N-Eupex size Speed factor Speed
Kr and Kw apply to smooth operation and an ambient temperature of -30° C to 80° C. Admissible misalignment Kr * Sn or Kw * Sn Sn = speed factor
Fig. 6.7 Axial misalignment
Kr and Kw may occur at the same time. The sum of the two misalignments must not exceed Kr or Kw.
In order to prevent accidents, the coupling must be protected against accidental contact with a protective device in accordance with DIN 31001.
6.4
Protective and control devices
The protective and control devices provided should be incorporated and connected up in accordance with the relevant instructions.
Fig. 6.5 Radial misalignment
A motor circuit breaker should be fitted. When working on live components, first remove the mains plug or switch off at the main switch and remove the fuse. Ensure that the motor cannot be started up while the work is being carried out.
6.5
Final tasks
The following final tasks should be carried out: 1. Check that the connecting flanges are airtight. 2. Check that the pump is running smoothly.
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K07V0001.ENG
7.
Start-up and Shut-down
7.1
Safety measures
Electrical connections must be made in accordance with the regulations of the local electricity company and the ELexV specifications. The German Chemistry Society’s guideline for hazardous locations must also be observed. This work must only be carried out by authorised personnel.
The motor may be switched on briefly in order to check the direction of rotation. If the direction of rotation is incorrect, the pump may be damaged. Never allow the pump to run against the prescribed direction of rotation. Only check the direction of rotation when the pump is full.
7.3
Start-up
7.3.1
Switching on
Switch on the motor. Fill the pump in accordance with the instructions, in order to avoid any risk of damage. When using hot media, fill the pump slowly in order to prevent distortion or thermal shocks. When using explosive, poisonous, hot or caustic media, ensure that they cannot endanger life or the environment. Adjust the flow at a constant pump speed and only on the discharge side. The control device on the inlet or supply side must always be fully open during operation.
7.2
Preparations for start-up
7.2.1
Filling the pump
Completely fill the pump with the medium to be pumped. Vent the pump at the flanges via the connection auxiliaries. This only needs doing once and, if necessary, can be carried out before the pipe is connected. The next time the pump is started up, it will prime itself automatically. Check the pump shaft to ensure that it is running smoothly. Check that all the connection auxiliaries are ready for operation. Open all the shut-off devices in the inlet and discharge pipes. When pumping media at temperatures > 100° C, the pump (body of the pump) should be warmed before start-up, ideally by filling it with the hot medium and allowing this to flow through until the body of the pump reaches roughly the same temperature as the medium (at least 10 minutes).
Never (even briefly) start or operate the pump when the discharge side is closed. Do not switch the pump on until the shut-off device is open. The slide valves in the inlet pipe must also be open. If a bypass pipe is fitted, it must be closed during inlet operation. During supply operation, it may remain open. After running the unit up to the nominal speed (see rating plate), adjust the pump head by slowly closing the valve on the discharge side. The priming time depends on the length of the inlet pipe and it will take a few seconds the first time the pump is used. If a foot valve or non-return valve is used in the inlet pipe, the pump will start to work as soon as it is switched on.
7.3.2
Setting the pumping capacity values
Once normal pumping has started, the flow can be adjusted. The operational data for the pump is given on the rating plate and in the data sheet. The pump head required should be monitored on the manometer display and, if it is not correct, it should be adjusted on the discharge side. Never run the pump with the discharge side closed, even during operation. If there is a possibility that the pressure in the pump’s cross-section at the discharge side could rise to an inadmissible level due to a malfunction during operation, suitable safety measures (e.g. fitting a safety valve) should be incorporated into the system.
Under no circumstances must the pump be allowed to run dry, since overheating could damage the pump components.
7.3.3
7.2.2
Safety measures (e.g. an overflow valve) should be incorporated into the system to ensure that the working pressure is not exceeded during operation on account of a malfunction.
Driving motor
The electrical connection work must be carried out by a qualified electrician, following the VDE and local regulations, particularly the protective measures. Check the operating voltage and speed of the motor. At 50 Hz, the speed should be 1450 rpm and at 60 Hz, it should be 1750 rpm. A motor circuitbreaker should be fitted.
7.2.3
Bearings
The bearings are adequately greased at the factory and are ready for operation.
7.2.4
Checking the direction of rotation
The direction of rotation of the motor must be the same as the rotation arrow on the pump. These arrows are marked on the pump. 02.10.95
Maintaining a minimum flow
In order to prevent damage to the pump, never run it against a closed shut-off valve in the discharge pipe.
The minimum flow is shown on the pump’s output curve (smallest proven Q value).
7.3.4
Temperature
Sudden changes in temperature (thermal shocks) should be avoided.
7.3.5
Liquids with a high specific gravity
If the specific gravity of the liquid pumped is greater than that specified in the order data (i.e. greater than the specific gravity on which the design of the pump was based), the performance of the pump will decrease, while the power consumption will increase. Ensure that the motor is not overloaded.
K07V0001.ENG
7.3.6
Higher flow rates
If the flow is greater than that specified in the order and design data, ensure that the available inlet height is still sufficient (Condition: NPSHavail > NPSHreq); otherwise, cavitation could occur, with damaging consequences . If the pump is used as a boiler feed pump, ensure that the pump is not used at a lower working pressure than the intended pressure. If the feed boiler is occasionally run at a lower working pressure, then the pump must be restricted to the normal working pressure of the boiler by means of a manual shut-off valve on the discharge side and a manometer connected to the discharge socket on the pump casing.
7.3.7
Switching frequency
The pump must not be switched on and off more than 10 times per hour.
7.4
Shut-down and restart
7.4.1
Switching off
The valves on the discharge and inlet sides must not be closed before the pump is stopped. Switch off the motor. Ensure that the pump runs down evenly. If non-return valves have been fitted, the shut-off devices may not close. For long stoppages and in the event of excess (feed) pressure on the inlet side, the shut-off valve on the inlet side should be closed. The auxiliary devices (sealing liquid, etc.) should be switched off. In the case of pumps in which the liquid is under vacuum, it is important to check before starting up again whether there is still enough liquid in the pump. The pump should be topped up if necessary. If the pump remains pressurised and hot, even when shut down, all the available sealing pipes should be opened. The sealing devices must remain switched on if there is a risk of taking in air (when the pump is supplied from vacuum installations or if pumps are operated in parallel with a common intake pipe). If there is a risk of frost, completely empty the pump and pipes.
7.4.2
Restart
Check that the pump shaft has stopped. If the non-return valve in the discharge pipe is not airtight, backflow of the pumped liquid may cause the pump shaft to rotate backwards. The pump must not be switched on if the pump shaft is rotating backwards, since this could result in damage to the pump.
7.5
Precautions in the event of long stoppages
If pumps are stored for long periods before installation, they should be protected against moisture and dirt (e.g. by wrapping them in oiled paper or plastic film). For other measures: see Section 3.7 Longterm storage and monitoring the preservation. If the pumps are stored, the inlet and discharge pipe sockets and all other intake and outlet sockets must immediately be closed off with blanking flanges or plugs. During storage, the pump should be rotated at least once a month (do not switch on since it will be running dry). The position of parts such as the shaft and ball bearings should be moved each time. If necessary, they can be released by lightly tapping the shaft in the axial direction. They must be replaced after no more than 4 years, since the grease will be unusable on account of ageing.
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For long stoppages, the pump should be filled with a suitable preservative agent. If there is a risk of frost, the pump, sealing circuit, etc, should be protected against freezing or drained and preserved.
K08V0003.ENG
8.
Maintenance
8.1
Safety measures
When carrying out maintenance and repair work, the information given in Section 2. Safety must be followed. The service life will be prolonged if monitoring and maintenance work is carried out regularly on the pump and drive.
8.2
General monitoring
The pump must never be operated dry or with an interruption in the flow. Check the liquid level in the inlet and feed tanks.
Never allow the flow to fall below the minimum or exceed the maximum level.
Monitor the speed and pump head.
Do not overload the drive motor.
The pumps and units should always run quietly and without vibration. All valves, filters, etc, on the inlet side should be kept completely open.
Check the pressure and temperature monitoring devices and the flow measuring devices.
Any standby pumps fitted should be brought into service once a week by switching on and off again.
8.3
Maintenance of components
8.3.1
Bearings and lubrication
The external roller bearings are greased for life. There is no need to lubricate the closed bearings. The temperature of the bearings must not exceed 80° C. If the pump is operating correctly, the bearings should be replaced after approximately 10,000 operating hours. The internal carbon sliding bearings should also be replaced after this period of operation. If excess temperatures are identified, this indicates damage to the bearings, and the deep-groove ball bearings should be replaced as soon as possible (see Section 9. Servicing ).
8.3.2
Flexible coupling
The condition of the flexible elements in the coupling should be checked at regular intervals. Note: Replace any worn flexible elements. The distance between the two halves of the coupling should be checked for the first time after approximately 1,000 operating hours (see Section 6.3.6 Checking the flexible coupling ). The rubber coupling blocks in the jaw clutch couplings should be checked. If there is significant wear, it must be assumed that the motor is not flush with the pump or that the distance between the two halves of the coupling has changed. This will result in damage to the pump’s bearings.
8.3.3
Drive
See the operating instructions provided by the drive manufacturer.
8.3.4
Mechanical seals
Mechanical seals require no maintenance, but will only remain leakfree if looked after. During operation, ensure that the mechanical seals never run dry and the conditions of use are within the limits for use of the selected mechanical seal. A leak of approximately 2.5 cm³ per hour is admissible.
02.10.95
If leaks occur at the mechanical seal, the seal cannot be tightened. We recommend dismantling and checking the mechanical seal, the shaft and the adjacent sealing elements. Since the service life of mechanical seals cannot normally be estimated, we recommend keeping a stock of spare seals.
K09V0012.ENG
9.
Servicing, disassembly and reassembly
9.1
All valves in the inlet, feed and discharge pipes must be closed.
Safety regulations All temperature.
For repairs carried out by your own personnel or by our specialist mechanics, ensure that the pump has been completely drained and cleaned. This applies in particular to pumps being sent to our factory or to one of our authorised service partners for repair. In order to protect our employees and the environment, we cannot accept for repair any pumps which are still full of pumping medium. If pumps containing pumping medium are sent to us, we will invoice the customer/owner for the costs of environmentally-friendly disposal. If pumps which have been operated with hazardous materials and/or media which represent a danger to the environment are sent for repair, the customer/owner must notify his own or our repair personnel on site or the staff at our factory or authorised service partner when the pump is returned for repair. In this case, the request for a customer service mechanic must be accompanied by details of the pumped liquid, for example in the form of a DIN safety data sheet. Hazardous materials are:
parts
must
have
returned
to
the
ambient
For repairs, the motor, baseplate and pipes should be should be removed from the pump.
9.3
Repairs to motors
Electrical repairs may only be carried out by a qualified electrician.
9.4
Disassembly
The relative positions of the individual parts of the casing should be marked before disassembly (e.g. with a chalk line) so that they can be reassembled in the correct position.
toxic materials
materials hazardous to the health
caustic materials
irritant materials
9.4.1
potentially explosive materials
combustible, highly flammable, readily flammable and flammable materials
carcinogenic materials
herbicidal materials
The integral mechanical seals require no maintenance. If, over a long period, leaks occur, the mechanical seal should be replaced. In so doing, it is not essential to remove the pump from the base plate or to disassemble the pipes. The design enables the mechanical seals to be replaced with the pump still installed, although the motor must be removed from the baseplate. The procedure for replacing the mechanical seal is as f ollows:
mutagenic materials
-A- Drive side:
materials which, in any other way, are dangerous to humans or to the environment
For all work on site, your own staff and our mechanics must be told about the hazards which might arise in connection with the repairs.. These instructions describe the most important disassembly and assembly work. The assembly steps described in the individual sections must be followed rigorously.
9.2
Notes before disassembly
Mechanical seals
1. On the pump side, remove the coupling half, loosen the screws (part 900) and remove the bearing cover (part 360). 2. Remove the circlip (part 932). 3. Remove the hex screws (part 901.1) and, using an extracting tool, pull the bearing bracket (part 330) together with the roller bearing (part 321) away from the shaft. 4. Strip off the thrower. 5. Remove the hex nuts from the bolts and pull the shaft seal casing (part 441), with the stationary seat (part 475) inside it, away from the casing seat.
During the guarantee period, the pump may only be opened by us or by one of our authorised service partners.
6. Remove the mechanical seal (part 433) from the shaft.
Outside the guarantee period, the pump should only be disassembled and reassembled by experienced personnel.
When removing the mechanical seal, ensure that the O-Ring is not damaged by the grooves on the shaft. -B- discharge side:
Before commencing disassembly, the unit must be secured to prevent it being switched on accidentally.
The pump housing must be depressurised and drained.
02.10.95
1. After loosening the screws (part 900), remove the bearing end cover (part 361). 2. As above (-A-) points 3-6. If a mechanical sealing part is worn, ensure that the parts sliding on one another (rotating seal and stationary seat) are replaced in pairs. The mechanical seal is assembled in the reverse order.
K09V0012.ENG
9.4.2
Disassembling the pump
To disassemble the pump, start from the side opposite the drive, after loosening the tie bolts (part 905). 1. Loosen the screws (part 900) and remove the bearing end cover (part 361). 2. Loosen and remove the tie bolts (part 905). 3. Remove the hex screws (part 901). Remove the screw plug (part 903) from the shaft seal casing. Using an extracting tool, pull out the bearing bracket (part 330) together with the deep groove ball bearing (part 321). Remove the thrower (part 507). Remove the hex nuts from the bolts and pull the shaft seal casing (part 441), with the stationary seat (part 475) inside it, away from the casing seat. Remove the foot (part 182) and discharge casing (part 107). 4. Disassemble the side channel casing (part 114), impeller (part 230), woodruff key (part 941), and discharge stage casing (part 109) and the stage heating jacket (part 109.3) if used, one after another. In the case of multiple-stage pumps, this disassembly sequence should be repeated as many times as there are stages. 5. The impellers (part 230) are not fixed in the axial direction and can be disassembled without the use of additional tools.
We recommend assembling the pump in a vertical position.
Assembly starts with the locating bearing. This can be found on the drive side. 1. At the marked position, pull the seal locating ring (part 500) down onto the shaft on the drive side and fix using a grub screw. Push the mechanical seal (part 433), and shaft seal casing (part 441) with the stationary seat (part 475) inside it, onto the shaft (part 210). Do not forget the gasket (part 400). 2. Follow with the spacer ring (part 525), thrower (part 507), and bearing bracket (part 330), with the deep groove ball bearing (part 321) inside it. 3. As an axial retainer, fit the circlip (part 932) on the end of the shaft. Screw down the bearing cover (part 360) and tighten the screws evenly. 4. Fit the key (part 940) and the coupling half on the pump side. There must be no resistance. Do NOT use a hammer. 5. Clamp the foot (part 182) in the vice. Place the pre-fitted shaft with all the parts described above onto the foot and temporarily fix the bearing bracket (part 330) using the hex screws (part 901). 6. Push the suction casing (part 106) onto the shaft.
6. Remove the suction casing (part 106) and remove the screw plug (part 903) from the shaft seal casing.
7. Seal the surfaces with gaskets (part 411).
7. Remove the bearing cover (part 360) and pull off the circlip (part 932).
Check the impeller gap dimensions (see section 11.1 Impeller gap dimensions).
8. Unscrew the bearing bracket (part 330) and remove using the extracting tool and, if necessary, pull out the deep groove ball bearing (part 321). Pull off the spacer ring (part 525).
9.5
Assembly
9.5.1
Tightening torque
9. When assembling the impeller, it must be slid against the discharge stage casing until it reaches the stop. The impellers are not fixed.
Tighten the tie bolts using a torque wrench. Bolt thread Tightening torque (Nm)
M 10
M 12
M 14
M 16
M 20
28
40
50
75
85
Values are not valid for condensate pumps for temperatures higher than 120 °C! Assembly instructions for tightening the connection screws for these pumps on request.
9.5.2
8. Depending on the number of stages, assemble the stage packages consisting of: discharge stage casing (part 109), woodruff key (part 941), impeller (part 230), and side channel casing (part 114), together with the bearing bush (part 545.1). The outer edge may be tapped lightly with a plastic hammer, but never the bearing surface.
Assembly
The pump is reassembled in the reverse order, with reference to the marks that were made before disassembly. The individual stage packages are offset to provide better absorption of the radial forces from the pump.
10. After the stage packages, the discharge casing (part 107) is then assembled. This is followed by the f oot (part 182). 11. Fit and loosely tighten the six tie bolts (part 905). Carefully align the pump on an adjustment plate. The pipe sockets must be parallel with the foot supporting surface. Using a torque wrench, tighten the tie bolts (part 905) using a diagonal sequence (see section 9.5.1 Tightening torque). 12. The bolts (part 902) of the shaft seal casing (part 441) on the drive side may now be tightened using a diagonal sequence, after first loosening the bearing bracket (part 330). After the shaft seal casing, the bearing bracket can also be tightened. 13. Using the grub screw, tighten the seal locating ring (part 500) at the marked position on the discharge side of the shaft. On the discharge side, the mechanical seal (part 433) is assembled using an assembly sleeve. Using the bolts (part 902), tighten the shaft seal casing (part 441) using a diagonal sequence (do not forget the gasket, part 400). Follow this with the thrower (part 507) and the bearing bracket (part 330) on the discharge side. 14. Using a sleeve, introduce the deep groove ball bearing (part 321) onto the shaft and into the bearing casing.
It is therefore particularly important to ensure that the individual stage packages are returned to their original positions. Close attention must be paid to the following points:
Parts which are to be reused must be thoroughly cleaned. Wash the sealing surfaces using solvent. Remove all residues of sealing rings and replace with new rings. All seals must be replaced.
Check parts for wear and order spare parts if necessary.
Replace bearing bushes if they are worn. (Please note: Do not lubricate the carbon sliding surfaces with Molykote G paste).
Rub Molykote G paste into all sliding surfaces, except the carbon sliding surfaces.
02.10.95
The sleeve for assembling the roller bearing must be designed so that the inner and outer roller bearing rings are driven evenly on the shaft or in the bearing casing. 15. Position the bearing end cover (part 361) and fix using two screws. 16. Screw the screw plug (part 903), with the sealing strip, into the shaft seal casing.
9.6
Post-assembly work
After assembly, bear the following points in mind:
Once the pump has been assembled, it should be possible to manually turn the shaft with a slight resistance. If any noise or
K09V0012.ENG
significant resistance is identified, give a few careful taps on the two shaft ends with a hard-headed hammer in the axial direction until the shaft turns easily.
Check the tightening torque of the hex nuts of the tie bolts, and tighten if necessary.
part number
part designation
material
liquid to be pumped
Pressurise the pump to 1.3 times the design pressure and check for leaks.
Reinstall the pump in the system, following the operating instructions.
The
Fit the protective guard and the safety and protective devices.
Check the direction of rotation.
Important: Only use the manufacturer’s original spare parts for repair and maintenance work. The use of other parts produced by yourself or not originating from the manufacturer will invalidate the guarantee.
Before starting up again, note the points listed in Section 7 Startup.
9.7.3
9.7
Spare parts
With respect to spare parts, we recommend keeping a stock of parts sufficient for two years’ continuous operation in accordance with the application guidelines contained in VDMA data sheet 24296.
9.7.1
Part No.
Spare parts for two years’ continuous operation in accordance with VDMA data sheet 24296 Designation
Number of pumps
(including
standby pumps)
5
6
8
10 + more
3
4
5
70%
3
4
5
70%
5
6
8
100%
2
2
3
40%
3
4
5
70%
5
6
8
100%
5
6
8
100%
5
6
8
100%
5
6
8
100%
2 3 4
114
109
230
Side channel casing with bearing bush, short, part 545.1 Discharge stage casing
set
Impeller
set
2 2 3
set 2 2 3
2 3 4 210
Shaft 1 1 2
321
Deep groove ball bearing
411
433
2 2 3
Stage casing gasket
set
Mechanical seal
set
2 3 4
2 3 4 475
Stationary seat
set 2 3 4
400
Seal 2 3 4
The gaskets should be replaced whenever the pump is reassembled.
9.7.2
Ordering spare parts
When ordering spare parts, please specify:
pump size
pump number
year of construction
02.10.95
This information is contained on the pump’s rating plate (see Section 12 Identification). pump number is also contained in the casing.
Storage, preservation
Spare parts should be stored away from chemical, corrosive and thermal influences. If necessary, metal parts should be preserved (see section 3.7 Long-term storage and monitoring the preservation and 7.5 Precautions in the event of long stoppages).
9.8
Standby pumps
For pumps in systems where system failure could put lives at risk or result in damage or additional costs, it is essential that you keep a sufficient number of standby pumps ready for operation within the plant, and that you ensure that they are ready for operation by means of regular inspections.
K10V0003.ENG
10.
Faults; causes and correction
10.1
Safety regulations
Troubleshooting must only be carried out by experienced technical personnel. In the event of a fault, the pump must be switched off as quickly as possible.
10.2
Faults and how to correct them
Faults
Cause
To correct
Pumping capacity too low
Counter-pressure too high.
Reset the operating point.
Suction lift too high or inlet height too low.
Check the liquid levels, open the shut-off devices on the inlet side.
Filter clogged.
Clean the filter and dirt trap on the inlet side.
NPSH not observed.
Sealing gap too large due to wear.
Replace the worn pump parts.
Wrong direction of rotation or speed.
Connect the motor up again.
Casing or inlet pipe not airtight.
Replace the casing seal. Check the flanged connections.
Pump not priming
Pump leaking
Temperature rise in the pump
02.10.95
Inlet pipe or shaft seal on the inlet side not Replace the casing seal. Check the flanged airtight. connections.
Suction lift too great.
Gaps between impeller and stage too large Replace the worn pump parts. due to wear.
Wrong direction of rotation.
Connect the motor up again.
Amount of liquid in the pum p too low.
Top the pum p up again
Inlet or discharge valve closed.
Open all the valves
Wrong pipe connection.
Connect the pump up again.
Wrong electrical connection.
Connect the motor up again.
NPSH not observed.
Clean the filter and dirt trap on the inlet side.
Stopper not removed.
Remove the stopper.
Casing screwed connection not airtight.
Check the tightening torque of the casing screws.
Seals defective.
Replace the seals.
Pum p or pipe not com pletely full.
Vent and fill t he pum p, inlet and feed pipes.
Suction lift too high or inlet height too low.
Check the liquid levels, open the shut-off devices on the inlet side.
Pump running dry.
Clean the filter and dirt trap on the inlet side.
Check the liquid levels.
K10V0003.ENG
Faults
Causes
Pump not running smoothly or is noisy
Pump or pipe not filled completely.
Suction lift too high or inlet height too low Check the liquid levels, open the shut-off devices (cavitation). on the inlet side.
Pump has fallen below Q-min..
Pump not standing evenly on the sub-floor or Check the pump installation. is distorted by tension.
Foreign bodies in the pump.
Dismantle and clean the pump.
Foreign bodies in the pump.
Dismantle the pump and replace the damaged parts.
Valve closed in the discharge pipe.
Open the shut-off devices.
Admissible pumping conditions not observed.
Note the pumping conditions specified in the data sheet.
Increase in output greater than the set upper Check the motor circuit-breaker and electrical threshold value. connections.
Increased friction in the pump.
Motor circuit-breaker tripping
02.10.95
To correct Vent and fill the pump, inlet and feed pipes.
Clean the filter and dirt trap on the inlet side.
Check whether:
the pump is blocked by impurities.
the shaft is mounted correctly.
K11V0003.ENG
11.
Associated documents
11.1
Impeller gap dimensions
Pump, material version 10, 12, 32, 60, 62 (t -40 °C Pump series Impeller width Depth on the discharge side 110 10 - 0.02 9.98 + 0.02 220/330 10 - 0.02 9.98 + 0.02 440 14 - 0.02 13.98 + 0.02 550 19 - 0.04 18.98 + 0.02 660 20 - 0.04 20.18 + 0.03
120 °C) Thickness of the seal 0.15 + 0.02 0.15 + 0.02 0.17 + 0.02 0.17 + 0.02 0.03
Pump, material version 10, 12, 32, 60, 62 (t 120° C Pump series Impeller width Depth on the discharge side 110 10 - 0.02 10.02 + 0.02 220/330 10 - 0.02 10.02 + 0.02 440 14 - 0.02 14.04 + 0.02 550 19 - 0.04 19.06 + 0.02
220° C) Thickness of the seal 0.15 + 0.02 0.15 + 0.02 0.17 + 0.02 0.17 + 0.02
Overall gap
Gap on each side
0.13 0.13 0.15 0.18 0.21
0.065 0.065 0.075 0.09 0.115
+ 0.06 + 0.06 + 0.06 + 0.1 + 0.05
+ 0.03 + 0.03 + 0.03 + 0.05 + 0.025
Overall gap
Gap on each side
0.17 0.17 0.21 0.23
0.085 0.085 0.115 0.115
+ 0.06 + 0.06 + 0.06 + 0.08
+ 0.03 + 0.03 + 0.03 + 0.04
The appendix contains: 11.2
Sectional drawing of the pump
11.3
Sectional drawing of the shaft seal (not for pumps with magnetic couplings)
11.4
Data sheet
The technical data for the pump is given in the data sheet. The dimensions are given in a table of measurements which will be sent to you upon request.
12.
Identification
Each pump has a company rating plate conforming to DIN 24 299 as shown in fig. 12.1.
Fig. 12.1
Pumps according to EEC guideline 94/9/EEC have an additional ATEX plate as shown in fig. 12.2 and 12.3.
Fig. 12.2
02.10.95
Fig. 12.3
K11V0120.eng
11.2
02.10.95
Sectional drawing of the pump Part no.
Designation
106 107 109.1 109.2 114 210 230 321 330 360 361 411 507 525 545.1 901.1-2 903 920.1 932 940 941
Suction casing Discharge casing Stage casing Stage casing -SGSide channel casing Shaft Impeller Deep groove ball bearing Bearing bracket Bearing cover Bearing end cover Stage casing gasket Thrower Spacer ring Bearing bushing Hex head screw Screw plug Hex nut Circlip Key Woodruf key
K11V0216.eng
11.3
02.10.95
Sectional drawing of the shaft seal Part no.
Designation
400.2 433.2 475.1 500 506.1 507 564.1 904
Gasket Mechanical seal Stationary seat Seal locating ring Retaining ring Thrower Taper pin Grub screw
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 15
Service Type: Description
Main LO um no.1 VAL 302/2R Vertical deepwell centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61356
45 870 930,00 -
930,00
4,70 4,70 147,00 200,00 1780
4,70 4,70 192,00 200,00 1780
-
Materials
Pump
Bearings Coupling Shaft seal
Casing : Cast iron GG-25 Impeller : Bronze G-CuSn10 Wear rings : Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : Type : S Material : NBR
Connections
suction side : pressure side
DN
PN
350
16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
CSM 315S/M-4 IM V1, IP 55, ISO B Transformer 440 / 60 230,00 230,00 368,00 2466,00
Pump / e-motor
(kg)
:
/
Classification
GL, certificate for pump and e-motor
Power supply Power Rated current Starting current
PTC : SPM : no Space heater : no
Weights
1.010,0
Total
(kg)
: 1.010,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 15
Service Type: Description
Main LO um no.2 VAL 302/2R Vertical deepwell centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61357
45 870 930,00 -
930,00
4,70 4,70 147,00 200,00 1780
4,70 4,70 192,00 200,00 1780
-
Materials
Pump
Bearings Coupling Shaft seal
Casing : Cast iron GG-25 Impeller : Bronze G-CuSn10 Wear rings : Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : Type : S Material : NBR
Connections
suction side : pressure side
DN
PN
350
16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
CSM 315S/M-4 IM V1, IP 55, ISO B Transformer 440 / 60 230,00 230,00 368,00 2466,00
Pump / e-motor
(kg)
:
/
Classification
GL, certificate for pump and e-motor
Power supply Power Rated current Starting current
PTC : SPM : no Space heater : no
Weights
1.010,0
Total
(kg)
: 1.010,00
16.02.2005
Manual N. 2000 - Rev. 03
LUBE-OIL
Data: 15/12/2004
VERTICAL PUMPS
VAL SERIES VERTICAL TURBINE PUMPS
INSTRUCTIONS MANUAL
AUDOLI & BERTOLA Division of GRUPPO ATURIA Piazza Aturia, 9 – 20060 Gessate (Milano) ITALY http:// www.gruppoaturia.com
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL SERIES VERTICAL TURBINE PUMPS Assembly, use and maintenance instructions
1
SAFETY INSTRUCTIONS ......................................................................................................................... 4 1.1
GENERAL ........................................................................................................................................... 4
1.2
SAFETY INSTRUCTIONS .................................................................................................................. 4
2
WARNINGS................................................................................................................................................ 5
3
STORAGE.................................................................................................................................................. 6
4
5
6
3.1
PUMPS................................................................................................................................................ 6
3.2
ELECTRIC MOTOR............................................................................................................................ 6
INSTALLATION .......................................................................................................................................... 7 4.1
PRELIMINARY INSPECTION............................................................................................................. 7
4.2
DRIVE MOTOR INSTALLATION AND CHECKING ........................................................................... 7
4.3
AXIAL IMPELLER ADJUSTMENT...................................................................................................... 8
4.4
DRIVE MOTOR INSTALLATION AND CHECKING ........................................................................... 9
START-UP................................................................................................................................................ 10 5.1
FIRST START-UP............................................................................................................................. 10
5.2
STOPPING........................................................................................................................................ 10
5.3
DURING OPERATION...................................................................................................................... 10
5.4
CHECKING AFTER LONG STORAGE ............................................................................................ 10
MAINTENANCE ....................................................................................................................................... 11 6.1
7
ROUTINE MAINTENANCE CHART ................................................................................................. 11
ASSEMBLY AND DISASSEMBLY........................................................................................................... 12 7.1
Disassembly for pump type VAL 152 without bearing bracket ......................................................... 12
7.2
Reassembly for pump type VAL 152 without bearing bracket.......................................................... 12
7.3
Disassembly for pump type VAL 152 with bearing bracket .............................................................. 13
7.4
Reassembly for pump type VAL152 with bearing bracket ................................................................ 13
7.5
Disassembly for pump type VAL 200................................................................................................ 16
7.6
Reassembly for pump type VAL 200 ................................................................................................ 16
7.7
Disassembly for pump type VAL 250................................................................................................ 19
7.8
Reassembly for pump type VAL 250 ................................................................................................ 19
7.9
Disassembly for pump type VAL 302 with centring sleeve ............................................................... 22
7.10
Reassembly for pump type VAL 302 with centring sleeve ............................................................ 22
7.11
Disassembly for pump type VAL 302 with keyed impeller ............................................................ 23
7.12
Reassembly for pump type VAL 302 with keyed impeller............................................................. 23
7.13
Disassembly for pump type VAL 349 with centring sleeve ........................................................... 26
7.14
Reassembly for pump type VAL 349 with centring sleeve ............................................................ 26
7.15
Disassembly for pump type VAL 349 with keyed impeller ............................................................ 27
7.16
Reassembly for pump type VAL 349 with keyed impeller............................................................. 27
7.17
Disassembly for pump type VAL 351 ............................................................................................ 30 2
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.18
Reassembly for pump type VAL 351............................................................................................. 30
7.19
ELECTRIC MOTOR BEARINGS................................................................................................... 33
7.20
CHECKS TO BE MADE AFTER DISASSEMBLY AND ASSEMBLY............................................ 33
8
RECOMMENDED SPARE PARTS .......................................................................................................... 34
9
TROUBLESHOOTING ............................................................................................................................. 35
10
ASSEMBLY SKETCHES...................................................................................................................... 36
11
TECHNICAL NOTICES ........................................................................................................................ 37
11.1
TIGHTENING TORQUE FOR IMPELLER LOCKED CONE ......................................................... 37
11.2
TYPE OF BEARING ...................................................................................................................... 37
11.3
CLEARANCE ALLOWABLE ON BEARING BUSHES [mm] ......................................................... 37
11.4
tightening torque for screws, nuts and bolts used for vertical turbine pumps N.m........................ 37
11.5
AXIAL IMPELLER BACKSLASH................................................................................................... 37
11.6
TYPE OF SHAFT SEAL RING ...................................................................................................... 38
11.7
FORCES AND MOMENTS ALLOWED ON HEAD ....................................................................... 38
11.8
AXIAL THRUST CALCULATION................................................................................................... 39
3
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
1
SAFETY INSTRUCTIONS
The pump supplied have been designed with safety in mind. Where hazards cannot be eliminated, the risk has been minimized by the use of guards and other design features. These instructions cannot cover all circumstances; YOU are responsible for using safe working practices at all times. Before carrying out any operation on the pump, always read the handbook. Subsequently, when using the pump, refer to the procedures described in the handbook step by step. The pump must be used in the conditions indicated in the order (which is to be considered as an integral part of this handbook). In particular, the pump must not be used at speed, capacity, pressure, temperature values and with different fluids from those for which it has been designed.
1.1 2 3
4
5
6 7 8
GENERAL ABCI products are designed for installation in designated areas, which are to be kept clean and free of obstruction that may restrict safe access to the controls and maintenance access points. Access to the equipment should be restricted to the personnel responsible for installation, operation and maintenance and they must be trained, adequately qualified and supplied with the appropriate tools for their respective tasks. All personnel that are responsible for installation, operation or maintenance of the equipment must have access to and study the instruction manual before any work is done and check that they will comply with all local and industry based safety instructions and regulations Ear defenders should be worn where the specified equipment noise level exceeds locally defined safe levels. Safety glasses or goggles should be worn where working with pressurized systems. Other personal protection equipment must be worn if local rules apply. DO NOT wear loose or frayed clothing or jewellery which could catch on the controls or become trapped in the equipment. READ the instruction manual before installation, operation or maintenance of the equipment. If the non compliance with certain safety instructions contained in this manual may hendanger human life, they are market by the following symbols
general safety is involved DIN4844-W9 ISO 3864-B 3.1.
electrical safety is involved DIN4844-W8 ISO 3864-B 3.6.
1.2 SAFETY INSTRUCTIONS ( For electric motor refer to the specific instructions before working on the group) 1.2.1 1
2
3 4
5 6
Pumps When lifting the pump use the lifting points specified on the outline drawing. Use lifting equipment have a safe working load rating suitable for the weight specified. Lift the component parts from their lifting points if provided or use suitable slings for lifting any part not provided with lifting points. DO NOT touch any moving or rotating parts. Guards are provided to prevent access to these parts, where they have been removed for maintenance they must be replaced before operating the equipment. Check and ensure that the pump operates below maximum working pressure specified in the manual. DO NOT touch surfaces which during normal running will be sufficiently hot to cause injury. These surfaces will remain hot after the pump has stopped, allow sufficient time to cooling before maintenance Original components do not contain hazardous material. Be cautions if some components as gasket have been substituted for wear that new parts don’t contain hazardous materials. Clear and easy access to all controls, gauges and dials must be maintained at all time.
1.2.2 Electric motor INSULATE the equipment before any maintenance work is done. Switch off the mains supply, remove fuses, apply lock-outs where applicable and affix suitable isolation warning signs to prevent inadvertent reconnection.
4
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
2
WARNINGS
This handbook gives detailed instructions for correct storage, installation, start-up, maintenance, disassembly and reassembly of VAL series vertical turbine pumps. Before carrying out any operation on the pump, always read the handbook (skipping any sections not applicable to the pump concerned). Subsequently, when using the pump, refer to the procedures described in the handbook step by step. The pump must be used in the conditions indicated in the order (which is to be considered as an integral part of this handbook). In particular, the pump must not be used at speed, capacity, pressure, temperature values and with different fluids from those for which it has been designed.
5
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
3
STORAGE
3.1
PUMPS
If -
the pump has been stored for long periods, take the following precautions before start-up: plug inlet to prevent penetration of foreign material store all components in a dry, well-ventilated vibration-free place rotate the pump by every 3 months, in order to prevent seizing and deformation of bearings
3.2
ELECTRIC MOTOR
Prior to installation, the motor must be stored in a dry, protected place far from sources of heat. In the case of long storage (more than 2 years), it is advisable to keep the motor in an air-tight plastic bag containing one or more bags of silica gel salt (from 35 to 100 g of salt according to motor size).
6
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
4
INSTALLATION
4.1
PRELIMINARY INSPECTION
The pump should be accessible for inspection and repair work. When lifting the pump use the lifting points specified on the outline drawing. Use lifting equipment having a safe working load rating suitable for the weight specified. Do not remove any protection or documents attached to the pump. The pump must be installed in a vertical position. Set down the pump into a tank from the tank upper part and fix it by tightening the bolts. Check flatness with a precision level. A vibration stopper must be provided at the tank bottom in order to prevent a shaking due to the ship's rolling and pitching. A flange for fastening the pump casing is placed at the top of the casing, so the stopper should be at 4 points. Always use correct equipment in a good state of repair. Use of improper equipment may not only damage the pump but may result in injury to personnel. Always comply with normal safety regulations when handling hanging loads. In particular, never stand beneath these.
4.2
DRIVE MOTOR INSTALLATION AND CHECKING
The electric motor is usually shipped disconnected from the pump but with the flexible half-coupling already fastened on the shaft. ALWAYS CHECK MOTOR DIRECTION OF ROTATION BEFORE MOUNTING IT ON THE HEAD OF THE PUMP. The direction of rotation is clockwise seen from above and looking at the motor from the fan side. The direction of rotation is also indicated by an arrow on the head of the pump. This check must not be made with the motor connected to the pump. Before mounting the motor on the pump, make the electrical connection, place it in a vertical position resting on the pedestal and apply power briefly. For the electrical connection, use cables of appropriate crosssection to avoid excessive voltage drops and overheating. Match the terminals according to the indications of the wiring diagram inserted in the terminal board. Before making any electrical connections, make sure that power is OFF. Failure to do so could be fatal. Make the ground connection using the specific terminal. Use an electric panel with safety device able to protect the motor against overloads and functioning with one phase missing. If the motor rotates in the opposite direction to that indicated by the arrow on the pump, reverse 2 of the wires on the terminal board, retry and then fix the ends marking these clearly to permit identification during subsequent maintenance operations and close the terminal board (any further reversal of the wires also in the electric panel must be avoided). At this point, assemble the motor. Bolt the motor flange to the base checking correct alignment of the connection. Centering of the pedestal is assured by the locator on the flange; check the distance between the half-couplings which must be between 3 and 5 mm. Make sure that the motor is adequately ventilated leaving sufficient space on the fan side . Tighten all the screws of rotating part protection devices; the pump must not be operated without the guards in place. The pump is now correctly installed and can be operated.
7
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
4.3
AXIAL IMPELLER ADJUSTMENT
IMPORTANT WARNING: THE MANUFACTURER GARANTEES CORRECT ADJUSTMENT FOR MACHINES THAT ARE SUPPLIED COMPLETELY ASSEMBLED. HOWEVER, ADJUSTMENT MUST ALWAYS BE CHECKED DURING COMMISSIONING. IN PARTICULAR, NO WARRANTY CLAIMS MAY BE MADE FOR ANY DAMAGES TO BE ASCRIBED TO INCORRECT AXIAL ADJUSTMENT. CUSTOMERS WHO RECEIVE THE PUMP DISASSEMBLED MUST THEREFORE PAY PARTICULAR ATTENTION TO THIS PARAGRAPH. 4.3.1 Adjustment procedure Unscrew the grub screws that close the pump side half pump coupling and unthread it, unscrew the hexagon socket screw of the bearing housing cover and extract it. At this moment, it is discovered the adjusting nut that it’ s blocked by a hexagonal socket screw, unscrewed it and rotate the nut in clockwise side so as to lower the shafting until the impeller rest on the bowl. Tap the end of the shaft with a lead hammer to assure that the above-mentioned operation is not hindered by any friction. Then turn the nut in an anticlockwise side until the pump can be rotated freely by hand. At this point, make the correct axial adjustment as described below. 4.3.1.1 Adjustment for pump type: VAL200-VAL250 Make the adjustment tightening the adjustment nut with a 1/3 turn in an anticlockwise direction if total head is less 50 m. or with 2/3 anticlockwise rotation if total head is between 50 and 100 m. Lock the adjustment nut with the hexagon socket screw inserting this in the nearest hole tightening in an anticlockwise direction. 4.3.1.2 Adjustment for pump type: VAL152-VAL302-VAL349-VAL351 Turn the adjustment nut in an anticlockwise direction for 1.5-2 turns. Lock in place with the hexagon socket screw. 4.3.2 Effect of incorrect adjustment Incorrect adjustment of the impeller may cause two irregularities: a) Higher power intake. The impellers scrape against the bowl. In this case, the adjustment nut must be turned in an anticlockwise direction as far as necessary. b) Reduced head or capacity in particular in the case of pumps with open impellers. In this case, repeat the adjustment procedure. Very imprecise adjustment may cause breakage of pump components.
8
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
4.4
DRIVE MOTOR INSTALLATION AND CHECKING
The electric motor is usually shipped disconnected from the pump but with the supporting pedestal mounted and the flexible half-coupling already fastened on the shaft. ALWAYS CHECK MOTOR DIRECTION OF ROTATION BEFORE MOUNTING IT ON THE HEAD OF THE PUMP. The direction of rotation is also indicated by an arrow on the head of the pump. This check must not be made with the motor connected to the pump. Before mounting the motor on the pump, make the electrical connection, place it in a vertical position resting on the pedestal and apply power briefly. For the electrical connection, use cables of appropriate crosssection to avoid excessive voltage drops and overheating. Match the terminals according to the indications of the wiring diagram inserted in the terminal board. Before making any electrical connections, make sure that power is OFF. Failure to do so could be fatal. Make the ground connection using the specific terminal. Use an electric panel with safety device able to protect the motor against overloads and functioning with one phase missing. If the motor rotates in the apposite direction to that indicated by the arrow on the pump, reverse 2 of the wires on the terminal board, retry and then fix the ends marking these clearly to permit identification during subsequent maintenance operations and close the terminal board (any further reversal of the wires also in the electric panel must be avoided). At this point, assemble the motor. Bolt the pedestal to the base checking correct alignment of the connection. Centering of the pedestal is assured by the locator on the flange; check the distance between the half-coupling which must be between 3 and 5 mm. Make sure that the motor is adequately ventilated leaving sufficient space on the fan side. The temperature of the working environment must not exceed 40°C except in the case of different rating of the motor, to be indicated in the technical specifications. If the motor is to be used in an environment at a higher temperature, consult our Engineering Office. NOTE: Tighten all the screws of rotating part protection devices; the pump must not be operated without the guards in place. The pump is now correctly installed and can be operated.
9
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
5
START-UP
5.1
FIRST START-UP
Make the following checks before first start-up: That the joint protection has been mounted in the motor stool. That no force or torque is applied to the delivery flange due to the weight of the pipe or caused by dilation of this. Check that electric motor and equipment are grounded in compliance with current legislation in the country of use. Failure to comply with regulations not only invalidates the warranty but may be highly dangerous for personnel. Close completely that on the discharge side Turn the pump shaft by hand to see whether it turns smoothly Make the above checks, connect the gauge and start the pump with the gate valve almost closed. Start the motor, but at first, repeat "ON" and "OFF" operations once or twice and enter into operation on confirming that there is no anomalous condition. If the pump does not vibrate, gradually open the gate valve until prescribed flow and head are reached. If an electric motor is used, check power take-off using an ammeter. When starting the pump subsequently check motor power supply.
5.2
STOPPING
Close the valve on the discharge. Stop the motor. When the pump stops suddenly during operation, switch off first of all and then close the valve on the discharge side.
5.3
DURING OPERATION
Be careful to operate as near the design point as practical Check the vibration and noise, If abnormal condition is surveyed, stop the pump immediately. Pay attention to bearing temperature rise. If the bearing housing can be felt by hand, there is no fear, otherwise, measure the temperature. The normal is liquid temperature plus 20°C. Never operate for more than 5 minutes with the valve closed on the discharge side, otherwise a temperature rise of the liquid in the casing will cause failure .
5.4
CHECKING AFTER LONG STORAGE
Carry out all the inspections indicated for initial start-up and also: - check the insulation resistance of the electric motor - check grounding - disassemble the electric motor and check its direction of rotation check that the pump rotates freely and is not clogged. Otherwise, try to release it by exerting force on the coupling. If the pump fails to rotate after exerting a torque of approx. 400 N on the coupling with a chain spanner, do not insist. The seized up pump must be disassembled and inspected by expert personnel.
10
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
6
MAINTENANCE
Wear a suitable mask or respirator when working with gasket components which contain fibrous material as these can be hazardous when the fibrous dust is inhaled. Be caution if other supplier’s components have been substituted for genuine ABCI parts, these may then contain hazardous materials. Excepting the case of abnormal conditions, it is preferable to carry out inspection periodically in the following way; the operator should make a final plan of inspection in accordance with conditions .
6.1
ROUTINE MAINTENANCE CHART
6.1.1 Every 3 months - check the wear of the elastic rubbers of the coupling - check up condition of oil lip seals - check the temperature of the bearing housing 6.1.2 Yearly or 8,000 hours - check the bolts tightening - check up conditions of "O ring" gaskets (if they are installed) 6.1.3 Every 4 years or 40,000 hours check up line bearing surfaces for wear conditions. check up impeller for conditions of wear or corrosion check shaft; conditions of contact, flaw in sliding faces and bend - check bearings; check up inner and outer faces as well balls for wear.
11
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7
ASSEMBLY AND DISASSEMBLY
Perform the following operations before disassembly of an installed pump: - Close the gate valve of the delivery pipe and disconnect the flange - Before opening the terminal board of the motor, make sure this is not live - Disconnect the electrical cables from the motor terminal board marking the position of the wires.
7.1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
12.
13. 14. 15.
7.2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
DISASSEMBLY FOR PUMP TYPE VAL152 WITHOUT BEARING BRACKET Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the "O-ring"(412), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.1), the bush (526) with key (940.1); dismantle the bearings (321), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Remove the column pipe (711) unfastening the hexagon head screws (901.2). Remove the top bowl (112) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
REASSEMBLY FOR PUMP TYPE VAL152 WITHOUT BEARING BRACKET A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 5mm.(see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112) complete with bearing inserting any gasket (400.1) and tightening the screws (901.1) Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711) on the upper bowl (112) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.2), and discharge head (115) on the shaft (213) and fix it on the column line flange (711) tightening hexagon head screws (901.3). Put bearings (321) into the bearing housing and fix with the locking ring (934.1). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjust ment, lock the nut with the hexagon socket screw (914). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the " O ring" (412) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards. 12
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15. 16.
7.4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
DISASSEMBLY FOR PUMP TYPE VAL152 WITH BEARING BRACKET Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the "O-ring"(412), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.1), the bush (526) with key (940.1); dismantle the bearings (321), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.7), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545.3). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
REASSEMBLY FOR PUMP TYPE VAL152 WITH BEARING BRACKET A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 5mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112) complete with bearing (545.1), any gasket (400.1) and tightening the screws (901.1). Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the bearing bracket (529) complete with bearing (545.3) onto the shaft, insert the second pipe (711.2) and fixed with hexagon head screws (901.7). Insert the discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321) into the bearing housing and fix with the locking ring (934.1). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the " O ring" (412) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards. 13
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL 152
14
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
PART. N° 112 115 138 213 230 321 341 350 360 400,1 400,2 400,3 400,4 412 420 522 523 526 531 545,1 545,2 653 711 731 861,1 861,2 901,1 901,2 901,3 901,4 901,5 904,1 904,2 904,3 914 920 924 931,1 931,2 934,1 934,2 940,1 940,2 400,5 529 545,3 711,1 711,2 901,7 904,1 920,2 931,3
DESCRIPTION DESCRIPTION
MATERIAL
CAST IRON PUMP BOWL CAST IRON DELIVERY CASING CAST IRON BELLMOUTH AISI 420 TOP SHAFT BRONZE IMPELLER STEEL RADIAL BALL BEARING CAST IRON MOTOR STOOL CAST IRON BEARING HOUSING STEEL BEARING COVER GUARNITAL PUMP BOWL GASKET GUARNITAL HEAD GASKET THROTTLING SLEEVE GASKET TEFLON TEFLON BEARING HOUSING GASKET NITRILIC RUBBER O-RING SEAL RUBBER/VITON SHAFT SEAL RING CAST IRON THROTTLING SLEEVE STEEL SPEEDY SLEEVE STEEL SAE 1040 CENTRING SLEEVE STEEL TENSION SLEEVE BRONZE BOWL BEARING BUSH BRONZE BELLMOUTH BEARING BUSH COPPER OIL SCOOP STEEL A72 COLUMN PIPE STEEL SCREWED CONNECTION COUPLING HALF SIDE MOTOR CAST IRON CAST IRON COUPLING HALF SIDE PUMP STEEL HEXAGON HEAD SCREW STEEL HEXAGON HEAD SCREW STEEL HEXAGON HEAD SCREW STEEL HEXAGON HEAD SCREW STEEL HEXAGON HEAD SCREW STEEL GRUB SCREW STEEL GRUB SCREW STEEL GRUB SCREW STELL HEXAGON SOCKET SCREW STEEL NUT STEEL ADJUSTING NUT STEEL LOCK WASHER STEEL LOCK WASHER STEEL SNAP RING STEEL SNAP RING STEEL KEY STEEL KEY FOR BEARING BRACKET GUARNITAL BEARING BRACKET GASKET CAST IRON BEARING BRACKET BRONZE BEARING BRACKET BUSH STEEL A 72 COLUMN PIPE STEEL A 72 COLUMN PIPE STEEL HEXAGON HEAD SCREW STEEL GRUB SCREW STEEL NUT STEEL LOCK WASHER 15
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15. 16.
7.6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
DISASSEMBLY FOR PUMP TYPE VAL 200 Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon screws (901.5); extract the bearing cover (360), the "O-ring"(412), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.1), the bush (526) with key (940.1); dismantle the bearings (321), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.7), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545.3). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112.1) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
REASSEMBLY FOR PUMP TYPE VAL 200 A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 5mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112.2) complete with bearing inserting any gasket (400.1) and tightening the screws (901.1) Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112.1) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.5), the bearing bracket (529) complete with bearing (545.3) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.7). Insert the gasket (400.2) and discharge head (115) on the shaft (213), fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321) into the bearing housing and fix with the locking ring (934.1). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon screws (901.5), after inserting the " O ring" (412) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards.
16
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL 200
17
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
DESCRIPTION PART. N° 112,1 112,2 115 138 213 230 321 341 350 360 400,1 400,2 400,3 400,4 400,5 412 420 522 523 526 529 531 545,1 545,2 545,3 653 711,1 711,2 731 861,1 861,2 901,1 901,2 901,3 901,4 901,5 901,6 901,7 901,8 904,1 904,2 904,3 914 920,1 920,2 924 931,1 931,2 931,3 934,1 934,2 940,1 940,2
DESCRIPTION PUMP BOWL PUMP BOWL DELIVERY CASING BELLMOUTH TOP SHAFT IMPELLER RADIAL BALL BEARING MOTOR STOOL BEARING HOUSING BEARING COVER PUMP BOWL GASKET HEAD GASKET THROTTLING SLEEVE GASKET BEARING HOUSING GASKET BEARING BRACKET GASKET O-RING SEAL SHAFT SEAL RING THROTTLING SLEEVE SPEEDY SLEEVE CENTRING SLEEVE BEARING BRACKET TENSION SLEEVE BOWL BEARING BUSH BELLMOUTH BEARING BUSH BRACKET BEARING BUSH OIL SCOOP COLUMN PIPE COLUMN PIPE SCREWED CONNECTION COUPLING HALF SIDE MOTOR COUPLING HALF SIDE PUMP HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW GRUB SCREW GRUB SCREW GRUB SCREW HEXAGON SOCKET SCREW NUT NUT ADJUST ING NUT LOCK WASHER LOCK WASHER LOCK WASHER SNAP RING SNAP RING KEY KEY
18
MATERIAL CAST IRON CAST IRON CAST IRON CAST IRON AISI 420 BRONZE STEEL CAST IRON CAST IRON STEEL GUARNITAL GUARNITAL TEFLON TEFLON GUARNITAL NITRILIC RUBBER RUBBER/VITON CAST IRON STEEL STEEL SAE 1040 CAST IRON STEEL BRONZE BRONZE BRONZE COPPER STEEL A72 STEEL A72 STEEL CAST IRON CAST IRON STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STELL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15. 16.
7.8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
DISASSEMBLY FOR PUMP TYPE VAL 250 Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screw (901.5); extract the bearing cover (360), the "gasket" (400.6), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545.2). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112.1) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bellmouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
REASSEMBLY FOR PUMP TYPE VAL 250 A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 5mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112.2) complete with bearing (545.1), inserting any gasket (400.1) and tightening the screws (901.1) Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112.1) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545.2) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.2) and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the " gasket" (400.6) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards.
19
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL 250
20
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
DESCRIPTION PART. N° 112,1 112,2 115 138 213 230 321 324 341 350 360 400,1 400,2 400,3 400,4 400,5 400,6 420 520 522 523 526 529 531 545,1 545,2 653 711,1 711,2 731 861,1 861,2 901,1 901,2 901,3 901,4 901,5 901,6 901,7 904,1 904,2 904,3 914,1 914,2 920 924 931,1 931,2 934,1 934,2 940,1 940,2
DESCRIPTION PUMP BOWL PUMP BOWL DELIVERY CASING BELLMOUTH TOP SHAFT IMPELLER RADIAL BALL BEARING AXIAL ROLLER BEA RING MOTOR STOOL BEARING HOUSING BEARING COVER PUMP BOWL GASKET HEAD GASKET THROTTLING SLEEVE GASKET BEARING HOUSING GASKET BEARING BRACKET GASKET BEARING HOUSING COVER GASKET SHAFT SEAL RING COVER SLEEVE THROTTLING SLEEVE SPEEDY SLEEVE CENTRING SLEEVE BEARING BRACKET TENSION SLEEVE BOWL AND BELLMOUTH BEARING BUSH BRACKET BEARING BUSH OIL SCOOP COLUMN PIPE COLUMN PIPE SCREWED CONNECTION COUPLING HALF SIDE MOTOR COUPLING HALF SIDE PUMP HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW GRUB SCREW GRUB SCREW GRUB SCREW HEXAGON SOCKET SCREW HEXAGON SOCKET SCREW NUT ADJUST ING NUT LOCK WASHER LOCK WASHER SNAP RING SNAP RING KEY KEY
21
MATERIAL CAST IRON CAST IRON CAST IRON CAST IRON AISI 420 BRONZE STEEL STEEL CAST IRON CAST IRON CAST IRON GUARNITAL GUARNITAL TEFLON TEFLON GUARNITAL TEFLON RUBBER/VITON BRONZE CAST IRON STEEL STEEL SAE 1040 CAST IRON STEEL BRONZE BRONZE COPPER STEEL A72 STEEL A72 STEEL CAST IRON CAST IRON STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STELL STELL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.9
DISASSEMBLY FOR PUMP TYPE VAL302 WITH CENTRING SLEEVE
1. 2. 3.
Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the gasket (400.4), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15. 16.
7.10
REASSEMBLY FOR PUMP TYPE VAL302 WITH CENTRING SLEEVE
1. 2. 3.
A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 150mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112) complete with bearing (545), inserting any gasket (400.1) and tightening the screws (901.1) Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.5),and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the gasket (400.4) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
22
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.11
DISASSEMBLY FOR PUMP TYPE VAL302 WITH KEYED IMPELLER
1. 2. 3.
Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the gasket (400.4), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the bell mouth (138) from the shaft (213) unfastening the hexagon head screws (901.1). Unscrew the nut (920.1) and remove the washer (550). The impeller (230) is removed from the shaft (213). After removing the washer (504.2), remove the top bowl (112) with the shaft bearing (545), unfastening the hexagon head screws (901.1). Remove the shaft protection sleeve (525.1), the spacer sleeve (525.2), the washer (504.1), the second impeller (230) and the second washer (504.1). Remove the second bowl (112) with shaft bearing (545). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable. If it is necessary to remove the shaft bearing (545) from the top bowl (112), remove the grub screw (904.1). If it is necessary, remove the wear rings (512) from the bell mouth (138) or from one of the two top bowls (112) removing the grub screw (904.1).
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
7.12
REASSEMBLY FOR PUMP TYPE VAL302 WITH KEYED IMPELLER
1.
The second pump bowl (112) complete with bearing (545) is fixed vertically to the column pipe (711.1) fastening the hexagon head screws (901.2). Place the pumps bowl (112) with the column pipe (711.1) horizontally. Insert the shaft (213) complete with keys (940.1 and 940.2). Slide the washer (504.1) until it abuts the shaft (213). Insert the impeller (230), the second washer (504.1), the spacer sleeve (525.2) and the shaft protection sleeve (525.1). Insert the second pump bowl (112) complete with bearing (545) on the shaft (213). Fix the pump bowl (112) to the second pump bowl (112) fastening the hexagon head screws (901.1). Insert the washer (504.2), the impeller (230), the washer (550) and fasten with the nut (920.1). Insert the bell mouth (138) and fix it to the first pump bowl (112) fastening the hexagon head screws (901.1). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.5),and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the gasket (400.4) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards. 23
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL 302 CENTRING SLEEVE IMPELLER VERSION
KEYED IMPELLER VERSION
24
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
DESCRIPTION PART. N° 112 115 138 213 230 321 324 341 350 360 400,1 400,2 400,3 400,4 400,5 420 504,1 504,2 512 520 522 523 525,1 525,2 526 529 531 545 550 653 711,1 711,2 731 861,1 861,2 901,1 901,2 901,3 901,4 901,5 901,6 901,7 904,1 904,2 914,1 914,2 920,1 920,2 924 931,1 931,2 931,3 934,1 934,2 940,1 940,2 940,3 940,4
DESCRIPTION PUMP BOWL DELIVERY CASING BELLMOUTH TOP SHAFT IMPELLER RADIAL BALL BEARING AXIAL ROLLER BEARING MOTOR STOOL BEARING HOUSING BEARING COVER PUMP BOWL GASKET THROTTLING SLEEVE GASKET BEARING HOUSING GASKET BEARING HOUSING COVER GASKET BEARING BRACKET AND HEAD GASKET SHAFT SEAL RING WASHER WASHER CASING WEAR RING COVER SLEEVE THROTTLING SLEEVE SPEEDY SLEEVE SHAFT PROTECTION SLEEVE SPACER SLEEVE CENTRING SLEEVE BEARING BRACKET TENSION SLEEVE BEARING BUSH WASHER OIL SCOOP COLUMN PIPE COLUMN PIPE SCREWED CONNECTION COUPLING HALF SIDE MOTOR COUPLING HALF SIDE PUMP HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW GRUB SCREW GRUB SCREW HEXAGON SOCKET SCREW HEXAGON SOCKET SCREW NUT NUT ADJUSTING NUT LOCK WASHER LOCK WASHER LOCK WASHER SNAP RING SNAP RING KEY KEY KEY KEY
25
MATERIAL CAST IRON CAST IRON CAST IRON AISI 420 BRONZE STEEL STEEL STEEL CAST IRON CAST IRON GUARNITAL TEFLON TEFLON TEFLON GUARNITAL RUBBER/VITON AISI 420 AISI 420 CAST IRON BRONZE CAST IRON STEEL AISI 420 AISI 420 STEEL SAE 1040 CAST IRON STEEL BRONZE STEEL COPPER STEEL A72 STEEL A72 STEEL CAST IRON CAST IRON STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STELL STELL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL STEEL
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.13
DISASSEMBLY FOR PUMP TYPE VAL349 WITH CENTRING SLEEVE
1. 2. 3.
Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the gasket (400.4), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15. 16.
7.14
REASSEMBLY FOR PUMP TYPE VAL349 WITH CENTRING SLEEVE
1. 2. 3.
A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 150mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112) complete with bearing (545), inserting any gasket (400.1) and tightening the screws (901.1). Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.5),and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the gasket (400.4) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
26
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.15
DISASSEMBLY FOR PUMP TYPE VAL349 WITH KEYED IMPELLER
18. 19. 20.
Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the gasket (400.4), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the bell mouth (138) from the shaft (213) unfastening the hexagon head screws (901.1). Unscrew the nut (920.1) and remove the washer (550). The impeller (230) is removed from the shaft (213). After removing the washer (504.2), remove the top bowl (112) with the shaft bearing (545), unfastening the hexagon head screws (901.1). Remove the shaft protection sleeve (525.1), the spacer sleeve (525.2), the washer (504.1), the second impeller (230) and the second washer (504.1). Remove the second bowl (112) with shaft bearing (545). After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable. If it is necessary to remove the shaft bearing (545) from the top bowl (112), remove the grub screw (904.1). If it is necessary, remove the wear rings (512) from the bell mouth (138) or from one of the two top bowls (112) removing the grub screw (904.1).
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.
7.16
REASSEMBLY FOR PUMP TYPE VAL349 WITH KEYED IMPELLER
21.
The second pump bowl (112) complete with bearing (545) is fixed vertically to the column pipe (711.1) fastening the hexagon head screws (901.2). Place the pumps bowl (112) with the column pipe (711.1) horizontally. Insert the shaft (213) complete with keys (940.1 and 940.2). Slide the washer (504.1) until it abuts the shaft (213). Insert the impeller (230), the second washer (504.1), the spacer sleeve (525.2) and the shaft protection sleeve (525.1). Insert the second pump bowl (112) complete with bearing (545) on the shaft (213). Fix the pump bowl (112) to the second pump bowl (112) fastening the hexagon head screws (901.1). Insert the washer (504.2), the impeller (230), the washer (550) and fasten with the nut (920.1). Insert the bell mouth (138) and fix it to the first pump bowl (112) fastening the hexagon head screws (901.1). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.5),and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the gasket (400.4) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards. 27
22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL 349 CENTRING SLEEVE IMPELLER VERSION
KEYED IMPELLER VERSION
28
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
DESCRIPTION PART. N°
DESCRIPTION
MATERIAL
112
PUMP BOWL
CAST IRON
115
DELIVERY CASING
CAST IRON
138
BELLMOUTH
CAST IRON
213
TOP SHAFT
AISI 420
230
IMPELLER
BRONZE
321
RADIAL BALL BEARING
STEEL
324
AXIAL ROLLER BEARING
STEEL
341
MOTOR STOOL
STEEL
350
BEARING HOUSING
CAST IRON
360
BEARING COVER
CAST IRON
400,1
PUMP BOWL GASKET
GUARNITAL
400,2
THROTTLING SLEEVE GASKET
TEFLON
400,3
BEARING HOUSING GASKET
TEFLON
400,4
BEARING HOUSING COVER GASKET
TEFLON
400,5
BEARING BRACKET AND HEAD GASKET
GUARNITAL
420
SHAFT SEAL RING
RUBBER/VITON
504,1
WASHER
AISI 420
504,2
WASHER
AISI 420
512
CASING WEAR RING
CAST IRON
520
COVER SLEEVE
BRONZE
522
THROTTLING SLEEVE
CAST IRON
523
SPEEDY SLEEVE
STEEL
525,1
SHAFT PROTECTION SLEEVE
AISI 420
525,2
SPACER SLEEVE
AISI 420
526 529
CENTRING SLEEVE BEARING BRACKET
STEEL SAE 1040 CAST IRON
545
BEARING BUSH
BRONZE
550
WASHER
STEEL
653
OIL SCOOP
COPPER
711,1
COLUMN PIPE
STEEL A72
711,2
COLUMN PIPE
STEEL A72
731
SCREWED CONNECTION
STEEL
861,1
COUPLING HALF SIDE MOTOR
CAST IRON
861,2
COUPLING HALF SIDE PUMP
CAST IRON
901,1
HEXAGON HEAD SCREW
STEEL
901,2
HEXAGON HEAD SCREW
STEEL
901,3
HEXAGON HEAD SCREW
STEEL
901,4
HEXAGON HEAD SCREW
STEEL
901,5
HEXAGON HEAD SCREW
STEEL
901,6
HEXAGON HEAD SCREW
STEEL
901,7
HEXAGON HEAD SCREW
STEEL
904,1
GRUB SCREW
STEEL
904,2
GRUB SCREW
STEEL
914,1
HEXAGON SOCKET SCREW
STELL
914,2
HEXAGON SOCKET SCREW
STELL
920,1
NUT
STEEL
920,2
NUT
STEEL
920,3
NUT
STEEL
924
ADJUSTING NUT
STEEL
931,1
LOCK WASHER
STEEL
931,2
LOCK WASHER
STEEL
931,3 934,1
LOCK WASHER SNAP RING
STEEL STEEL
934,2
SNAP RING
STEEL
940,1
KEY
STEEL
940,2
KEY
STEEL
940,3
KEY
STEEL
940,4
KEY
STEEL
29
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.17
DISASSEMBLY FOR PUMP TYPE VAL351
1. 2. 3.
Unscrew the fixing bolts of the discharge head to the base-plate and remove the whole pump unit. Unfasten the protection device locking screws and remove these. Disassemble the electric motor; unscrew nuts of bolts; the half-coupling will remain on the motor shaft. Unscrew the grub screws (904.2) and extract half-coupling pump side (861.2). Unscrew the hexagon head screws (901.5); extract the bearing cover (360), the gasket (400.4), and the lip seal (420). Remove the speedy sleeve (523) located in the shaft (213). Unscrew the locking hexagon socket screw (914.2) of the adjustment nut and the adjustment nut (924). Remove locking ring (934.2), the bush (526) with key (940.1); dismantle the bearings (321-324), and clear with compressed air. Unscrew the hexagon head screws (901.3) located on the column line flange and remove the discharge head (115). Unscrew the hexagon head screw (901.6), extract the column pipe (711.2) and bearing bracket (529) with the line shaft bearing (545). Remove the column pipe (711.1) unfastening the hexagon head screws (901.2). Remove the top bowl (112) unfastening the hexagon head screws (901.1). The impeller (230) is fastened to the shaft (213) with a threaded collect with lock-nut and washer (531), which must be removed. Proceed as follows starting from the upper impeller. Unscrew the ring nut and remove it from the shaft (213) together with the washer. Fit an approx. 3 kg pipe over the shaft. The bore of the ring must be 0.3 mm larger than the diameter of the shaft. Continue to tap on the impeller until the protruding part of the collect frees the impeller. After removing the first impeller, proceed as described above to remove the remaining stages. Remove the bell mouth (138) from the shaft (213).
4. 5. 6. 7. 8. 9. 10. 11. 12.
13.
14. 15.
After disassembly, thoroughly clean all parts checking these for wear and if necessary replace any parts no longer suitable.
7.18
REASSEMBLY FOR PUMP TYPE VAL351
1. 2. 3.
A screw and two washers must be attached to the lower end of the shaft. The diameter of the spacer must be equal to that of the shaft with thickness of 180mm. (see Fig.1). At this point, insert the shaft (213) vertically in the bell mouth (138) complete with bearing, shimming the lower end of the shaft so that the larger washer rests against the pump body. Fit the collect into the impeller (230) with the collect lock nut and washer loosely fitted (531). Slide the impeller into the shaft until it abuts the bell mouth (138). Secure in position with the collect lock nut and washer. Slide in the pump bowl (112) complete with bearing (545), inserting any gasket (400.1) and tightening the screws (901.1) Assemble the other stages following the same procedure. Once assembly has been completed, unfasten the screw and remove the washer. Insert the pipe (711.1) on the upper bowl (112) inserting the gasket (400.1) and lock in place with the hexagon head screws (901.2). Insert the gasket (400.5), and bearing bracket (529) complete with bearing (545) onto the shaft, insert the gasket (400.5), the second pipe (711.2) and fixed with hexagon head screws (901.6). Insert the gasket (400.5),and discharge head (115) on the shaft (213) and fix it on the column line flange (711.2) tightening hexagon head screws (901.3). Put bearings (321-324) into the bearing housing and fix with the locking ring (934.2). Fit the bush and insert the key (940.1) into its side. Insert the adjustment nut (924) and proceed with impeller axial adjustment. After adjustment, lock the nut with the hexagon socket screw (914.2). Insert the speedy sleeve (523) in the shaft (213). Fix the bearing cover (360) with hexagon head screws (901.5), after inserting the gasket (400.4) and the lip seal (420). Install on the shaft (213) half coupling pump side (861.2) with its gommets. Put the key (940.2) into its site on the shaft. Assembly electric motor with its half coupling. Bolt on the guards.
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
30
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
VAL351
31
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
DESCRIPTION PA RT . N ° 1 12 1 15 1 38 2 13 2 30 3 21 3 24 3 41 3 50 3 60 4 00,1 4 0 0 ,2 4 0 0 ,3 4 0 0 ,4 4 00,5 4 20 5 12 5 20 5 22 5 23 5 26 5 29 5 31 5 45 6 53 7 11,1 7 11,2 7 31 8 6 1 ,1 8 6 1 ,2 9 0 1 ,1 9 0 1 ,2 9 0 1 ,3 9 0 1 ,4 9 0 1 ,5 9 0 1 ,6 9 0 1 ,7 9 0 4 ,1 9 0 4 ,2 9 0 4 ,4 9 1 4 ,1 9 1 4 ,2 9 2 0 ,1 9 2 0 ,2 9 24 9 3 1 ,1 9 3 1 ,2 9 3 1 ,3 9 3 4 ,1 9 3 4 ,2 9 4 0 ,1 9 4 0 ,2
DESCRIPTION PUMP BOWL DELIVERY CASING BELLMOUTH TOP SHAFT IMPELLER RADIAL BALL BEARING AXIAL AXI AL ROL LER BEA RING RIN G MOTOR STOOL BEARING HOUSING BEARING COVER PUMP BOWL GASKET THROTTLING SLEEVE GASKET BEARING HOUSING GASKET BEARING HOUSING COVER GASKET BEARING BRACKET AND HEAD GASKET SHAFT SEAL RING CASING WEAR RING COVER SLEEVE THROTTLING SLEEVE SPEEDY SLEEVE CENTRING SLEEVE BEARING BRACKET TENSION SLEEVE BEARING BUSH OIL SCOOP COLUMN PIPE COLUMN PIPE SCREWED CONNECTION COUPLING HALF SIDE MOTOR COUPLING HALF SIDE PUMP HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW HEXAGON HEAD SCREW GRUB SCREW GRUB SCREW GRUB SCREW HEXAGON SOCKET SCREW HEXAGON SOCKET SCREW NUT NUT ADJUST ADJ UST ING NUT LOCK WASHER LOCK WASHER LOCK WASHER SNAP RING SNAP RING KEY KEY
32
M A T E R IA L C A S T IR O N C A S T IR O N C A S T IR O N A IS I 4 2 0 B RON ZE S TEE L S TEE L S TEE L C A S T IR O N C A S T IR O N G U A R N IT A L T EFL ON T EFL ON T EFL ON G U A R N IT A L R U B B E R /V IT O N C A S T IR O N B RON ZE C A S T IR O N S TEE L S TE EL S AE 1040 C A S T IR O N S TEE L B RON ZE CO PP ER S TE EL A 72 S TE EL A 72 S TEE L C A S T IR O N C A S T IR O N S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TE LL S TE LL S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L S TEE L
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
7.19
ELECTRIC MOTOR BEARINGS
To disassembly electric motor bearings use a suitable puller. To reassembly electric motor bearings use a press and a suitable hose that must act only on internal ball bearing ring ( not on external ring). Reassembly can also be executed heating bearings in hot oil 80°C (approx.) and quickly mount on the shaft.. If ball bearing are sealed type, protection shall be installed motor side. After reassembly, reassembly, check that internal internal bearing bearing rings rings lean to the shoulder shoulder provided provided on the the shaft.
7.20
CHECKS TO BE BE MADE MADE AFTER DISASSEMBLY AND ASSEMBLY
Check for any parts that could foul rotating parts. Check that no force or torque is exerted on the delivery flange due to the mechanical action of pipes or thermal expansion. Check pump-motor alignment.
33
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
8
RECOMMENDED SPARES PARTS
DENOMINATION
x 1 year
x 2 years
x 4 years
Impeller
X
Impeller lock
X
Pump bearings
X
Shaft Lip seals
X X
O-ring
X
Coupling gommets
X
Bearings
X
34
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
9
TROUBLESHOOTING MALFUNCTION
CAUSES AND remedy
Electric motor current intake is too high
- Check total head. If it is too low, partially close the gate valve. valve.
Output or total head is unsatisfactory
- Check the level in the tank with the pump operating - Check that the impellers are correctly adjusted - Check that the speed of the pump vertical shaft is correct - Check that no air is sucked in at the inlet. - Check the impellers for wear and if necessary replace.
The pump vibrates or is noisy
- Head is much lower than rated. Partially close the gate valve. - Insufficient submersion causes suction of air at inlet; inlet; insert a diffusion disk disk - Check tightness of discharge head lock nuts
The discharge head is too hot
- Check head alignment
The pump vibrates during start-up
- Insufficient submersion submersion causes suction of air at inlet; increase submersion or insert a diffusion disk
35
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
10
ASSEMBLY SKETCHES
NOTE: for keyed impeller execution spacer is not necessary. 36
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
11
TECHNICAL NOTICES
11.1
TIGHTENING TORQUE FOR IMPELLER LOCKED CONE TYPE OF PUMP VAL152 VAL200 VAL250 VAL302 VAL349 VAL351
11.2
TYPE OF BEARING TYPE OF PUMP VAL152 VAL200 VAL250 VAL302 VAL349 VAL351
11.3
AXIAL BEARING
29416E 29416E 29416E 29416E
JOURNAL BEARING 7316 7316 6034 6034 6034 6034
maximum 0.50
TIGHTENING TORQUE FOR SCREWS, NUTS AND BOLTS BOLTS USED FOR VERTICAL TURBINE PUMPS N.m
THREADED CI 80 WRENCH SIZE M6 7,5 10 M8 23,5 13 M10 5 0,5 17 M12 89,5 19 M14 145 22 M16 215 24 M18 310 27 M20 435 30 M22 580 32 M24 735 36 resistance when when specified specified in the order. order. Use these values for high resistance
11.5
Q.TY 2 2 1 1 1 1
CLEARANCE ALLOWABLE ON BEARING BUSHES [MM]
standard 0.25-0.30 11.4
RPM MAX MAX TORQ TORQUE UE N.m N.m DIAMETER OF SHAFT RPM 70 40 1770 200 45 45 1 7 7 0 1 75 1770 365 50 1770 590 60 1770 1070 70 1770 1290 70
AXIAL IMPELLER BACKSLASH PUMP
BACKSLASH mm mm
VAL152 VAL200 VAL250 VAL302 VAL349 VAL351
8 10 15 8 12 11 37
CI 100* 10,5 33,5 71 125 200 300 440 615 820 1040
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
11.6
TYPE OF SHAFT SEAL RING PUMP
SIZE OF SEAL
TYPE OF SPEEDI-SLEEVE
DIMENSION OF SHAFT
VAL152 VAL200 VAL250 VAL302
35x47x8 35x47x8 45x62x7,5 55x80x10 55x80x10 60x85x8 55x80x10 60x85x8
1 1 2 2 2 3 2 3
35 35 55 55 55 60 55 60
VAL349 VAL351
SPEEDY-SLEEVE
TYPE 1 2 3
11.7
REF. SHAFT 35 55 60
"A" SHAFT DIAMETER MIN 34,94 54,94 59,92
MAX 35,08 55,08 60,07
"X" "Y" "D" "Z" LENGHT UPPER TOTAL FLANGE INSTALLATION SHAFT LENGHT DIAMETER DEPTH 13 20 20
16 23 23
41,6 62 70,7
20 35 32
FORCES AND MOMENTS ALLOWED ON HEAD
HEAD TYPE
DN
BA 40 BA 70
200 350
FORCES (daN) Fy 160 280
Fz 200 350
Fx 180 315 38
MOMENTS (mdaN) F 315 550
My 95 230
Mz 70 165
Mx 80 190
M 145 340
Manual N. 2000 – Rev. 03
LUBE-OIL Data: 15/12/2004
VERTICAL PUMPS
11.8
AXIAL THRUST CALCULATION
PUMP TYPE VAL152 VAL200 VAL250 VAL302 VAL349 VAL351
FACTOR K 12 27 42 46 65 69
ROTATING WEIGHT FOR STAGE A=kg. 10 13 21 39 44 47
N° 1 METER LINE SHAFT WEIGHT B
mm
Kg/m.
40 45 50 60 70 70
10,5 13 16,5 24 33 33
ROTATING PART AND COUPLING WEIGHT C=kg. BA 40 = 30
BA 70 = 90
AXIAL THRUST= K x Head m.= S ROTATING WEIGHT FOR STAGE= A x N° IMPELLER = T 1 METER LINE SHAFT WEIGHT= B x 1 METER LINE SHAFT WEIGHT = V ROTATING PARTS AND COUPLING WEIGHT OF THE DISCHARGE HEAD= C TOTAL AXIAL THRUST= S+T+V+C
39
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 16
Service Type: Description
Central FW um no.1 VRF 9/350 G Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61358
36 1000 820,00 1,50 4,00 2,50 81,40 89,50 1780 5,60
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Mechanical seal Carbon-SiC NBR DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29731 BH, T.P. 7 bar 02 GL 05 E-motor : 14845 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 99,00 154,00 1091,00
E-Motor Nr.
: QA 31574
PTC : SPM : no Space heater : no
Weights
755,00
/
802,00
Total
(kg)
: 1.557,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 16
Service Type: Description
Central FW um no.2 VRF 9/350 G Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61359
36 1000 820,00 1,50 4,00 2,50 81,40 89,50 1780 5,60
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Mechanical seal Carbon-SiC NBR DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29732 BH, T.P. 7 bar 02 GL 05 E-motor : 14845 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 99,00 154,00 1091,00
E-Motor Nr.
: QA 31567
PTC : SPM : no Space heater : no
Weights
755,00
/
802,00
Total
(kg)
: 1.557,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 16
Service Type: Description
Central FW um no.3 VRF 9/350 G Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61360
36 1000 820,00 1,50 4,00 2,50 81,40 89,50 1780 5,60
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Bronze G-CuSn12 Stainless steel Rolling contact grease flexible spacer Mechanical seal Carbon-SiC NBR DN 300 300
PN 10 10
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29733 BH, T.P. 7 bar 02 GL 05 E-motor : 14845 H 12 GL 04
Power supply Power Rated current Starting current
WEG CSM 280 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 99,00 154,00 1091,00
E-Motor Nr.
: QA 31566
PTC : SPM : no Space heater : no
Weights
755,00
/
802,00
Total
(kg)
: 1.557,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 1 of 8
3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 2 of 8
5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 4 of 8
6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 5 of 8
7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 7 of 8
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 160 161.2 211.2 230 320 322 332 341 360 400.1 400.2 420.1 420.2 421 470 502.1 502.2 540 554.1 554.2 554.3 554.4 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.2 902.3 902.4 902.5 903.1
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Deckel Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung Flachdichtung V-Ring V-Ring Simmerring Gleitringdic htung Spaltri ng Spaltri ng Buchs e Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube
Volute casing Cover Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket Gasket V-ring V-ring Simmer ring Mechanical seal Wearin g rin g Wearin g rin g Bush Washer Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug
Corps à volut e Couvercl e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joint Joi nt à lèvres Joi nt à lèvres Anneau de retenue Garnitu re mécanique Bague d`usu re Bague d`usu re Douille Disque Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014G Blatt 1
Behrens Pumpen Teil Item Benennung Repère 903.2 Verschl ußschraube
Designation
Dèsignation
Plug
Boucho n
903.3
Verschl ußschraube
Plug
Boucho n
912.1
Entleerungss topfen
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
920.5
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.3
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014G Blatt 2
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 17
Service Type: Description
Ballast um no.1 VRF 7/350S Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61361
32 1030 500,00 2,50 2,50 54,20 59,60 1775 5,10
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible spacer Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 250 250
PN 10 10
Type
: self-priming unit AELE - 45 level switch controlled, air driven selfpriming unit mounted on pump
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29734 BH, T.P. 7 bar 02 GL 05 E-motor : 14846 H 12 GL 04
Self-priming unit Prime mover
E-Motor
Power supply Power Rated current Starting current
WEG CSM 250 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 63,00 97,30 729,00
E-Motor Nr.
: QA 31024
PTC : SPM : no Space heater : yes
Weights
785,00
/
460,00
Total
(kg)
: 1.245,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item 17
Service Type: Description
Ballast um no.2 VRF 7/350S Vertical inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61362
32 1030 500,00 2,50 2,50 54,20 59,60 1775 5,10
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible spacer Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 250 250
PN 10 10
Type
: self-priming unit AELE - 45 level switch controlled, air driven selfpriming unit mounted on pump
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump and e-motor Pump : 29735 BH, T.P. 7 bar 02 GL 05 E-motor : 14846 H 12 GL 04
Self-priming unit Prime mover
E-Motor
Power supply Power Rated current Starting current
WEG CSM 250 S/M-4 IM V1, IP 55, ISO B DOL 440 / 60 63,00 97,30 729,00
E-Motor Nr.
: QA 31025
PTC : SPM : no Space heater : yes
Weights
785,00
/
460,00
Total
(kg)
: 1.245,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 4 of 8
6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 5 of 8
7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 6 of 8
9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 7 of 8
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 8 of 8
Behrens Pumpen Teil Item Repère 102 161.1 211.1 230 320 322 332 341 360 400.1 420.1 421 452 461 502.1 502.2 524 554.1 554.2 554.3 636 720 860.1 860.2 860.3 860.4 867 900 901.1 902.1 902.2 902.3 902.4 903.1 903.2 903.3
Type: VRF
Benennung
Designation
Dèsignation
Spiralgehäuse Gehäusedeckel Pumpenw elle Laufrad Doppelrillenkugellager Pendelroll enlager Lagerstuhl Antr iebslaterne Lagerdeckel Flachdichtung V-Ring Simmerring Stopfbuc hsbri lle Stopfbuc hspackung Spaltri ng Spaltri ng Wellensch utzhü lse Unterlegs cheib e Unterlegs cheib e Unterlegs cheib e Schmi ernip pel Langnippel Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungsteil Kuppl ungspu ffer Ringschraube Sechskant sch raube Stiftsc hraube Stiftsc hraube Stiftsc hraube Stiftsc hraube Verschl ußschraube Verschl ußschraube
Volute casing Cover of casin g Pump shaft Impeller Ball bearing Roller bearing Bearing seat Motor suppor t Cover of bearing Gasket V-ring Simmer ring Stuffing box gland Packing Wearin g rin g Wearin g rin g Shaft pro tect ion sleeve Washer Washer Washer Grease nip ple Barrel nipple Coupling part Coupling part Coupling part Coupling part Coupling packing Lift ing eye screw Hexagon head scr ew Stud screw Stud screw Stud screw Stud screw Plug Plug
Corps à volut e Couvercl e de cor ps Arb re de pom pe Roue circ ulatrice Roulement à billes Roulement à bil les Coussinet Support de moteur Couvercl e de palier Joint Joi nt à lèvres Anneau de retenue Bride de presse-étoupe Garnitu re Bague d`usu re Bague d`usu re Chemise d´arbre Disque Disque Disque Graisseur Tuyau à double nipple Accou plement Accou plement Accou plement Accou plement Intercalaires d`accoupl ement Vis Vis à tête hexagonale Prisonnier Prisonnier Prisonnier Prisonnier Boucho n Boucho n
Verschl ußschraube
Plug
Boucho n
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 1
Behrens Pumpen Teil Item Benennung Repère 912.1 Entleerungss topfen
Designation
Dèsignation
Plug
Boucho n
912.2
Entleerungss topfen
Plug
Boucho n
914.1
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
914.2
Innensechskantschraube
Socket head cap screw
Vis à six pans creux
920.1
Sechskant mut ter
Nut
Ecrou hexagonal
920.2
Sechskant mut ter
Nut
Ecrou hexagonal
920.3
Sechskant mut ter
Nut
Ecrou hexagonal
920.4
Sechskant mut ter
Nut
Ecrou hexagonal
922
Laufradmutter
Impeller nut
Ecrou de roue
923
Kontermut ter
Contre nut
Ecrou de arbre
940.1
Paßfeder
Fitt ing key
Resso rt d`ajust age
940.2
Paßfeder
Fitt ing key
Resso rt d`ajust age
Type: VRF
Stückliste Spare part list Specification des pieces dètachèes
1014P Blatt 2
TYP/TYPE AELE 35/45/55/65
PD-AELE-11-BEHRENS-GB.DOC
Table of contents 1 Commissioning 2
Maintenance and repair
2.1 Disassembly and assembly of the compressed air ejector 2.2 Disassembly and assembly of the jet system 2.3 Disassembly and assembly of the shut-off system 3
Appendix
3.1 Dimensions 3.2 Spare parts 3.2 Circuit Diagramm
Operating voltage Enclosure Power input Nominal pressure Compressed working air required Material: Float chamber Ejector casing Nozzle system Inner parts Sealings Size of Nozzle: Suction capacity max. Air consumption at 6 bar Pressure-Stage: Switch-on Point Switch-off Point
220V-230V 50/60 Hz IP65 16 VA PN 10 5 - 7 bar Bronze GCuSn10 Bronze GCuSn10 Polyetylene Stainless Steel NBR 35 Nl/min 300 l/min 70 bar bar
Connections: Venting suction side Venting discharge side Exhaust, Drainage Pressure switch Cable Compressed working air
1
45 500 120 U 0,3 0,5
55 700 180 V 0,6 1,1
A1 A2 B C E P
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
65 1000 240 W 1,1 1,6
TYP/TYPE AELE 35/45/55/65
1.
PD-AELE-11-BEHRENS-GB.DOC
Commissioning
For commissioning pay attention to following steps: - Check all pipe connections and pipes for proper lay and leakage. - Check all electrical connections. - Check the compressed air connection Caution Please pay attention to modification for special design. 2.
Maintenance and repair
The system functions with slightly maintenance work. Following inspections respectively work should be performed in fixed intervals which depend on pumping medium, operation mode and operation time. - Check all components for proper function 2.1 Disassembly and assembly of the compressed air ejector
Before starting work, the compressed air ejector must be switched to a power off mode.
Before starting work, the compressed air ejector must be disconnected from the compressed air supply. Starting torque for the thread connections are to be taken from the corresponding DIN-Norm. Caution We advise to exchange all sealings at repair work. Disassembly of the compressed air ejector: - Take off cable plug at the solenoid valve of the compressed air ejector. - Loosen the exhaust and compressed air pipe. - Loosen the assembling screws of the compressed air ejector and remove the compressed air ejector Assembly takes place in reversed order. 2.2 Disassembly and assembly of the jet system - Fix the compressed air ejector and turn out the long nibble. - Pull out the mixing jet of the casing - Take out the driving jet of the casing. Assembly takes place in reversed order. Caution The long nipple has to be screwed on the casing powerful. The check nut may not to be twisted.The long nipple must be fitted with a bolt protection medium (e.g. Loctite). 2.3 Disassembly and assembly of the shut-off valve - Loosen the pressure switch casing at the compressed air ejector
Pressure switch casing is spring pressurized. -
Take out the compression spring and loosen the safety nut at the spring seating. Use the safety nut at the piston (jet side) for supporting. - Take out spring seating, guide ring and valve seling of the compressed air ejektor. - Take out the Piston rod with mounted piston. Assembly takes place in reversed order. Caution When assembling the piston the gasket is to be pressed via compressed air supply by a similar formed tool. vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
2
TYP/TYPE AELE 35/45/55/65
3.
Appendix
3.1 Dimensions
13413d/A4
3
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
PD-AELE-11-BEHRENS-GB.DOC
TYP/TYPE AELE 35/45/55/65
PD-AELE-11-BEHRENS-GB.DOC
3.2 Spare parts
14153b/A4
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
4
TYP/TYPE AELE 35/45/55/65
3.3 Circuit diagramm Circuit diagramm of the aspirator
Recommended connecting plan for time delayed starting of the centrifugal pumps.
30176/A3
5
vatec-Maschinenbau GmbH · e-mail:
[email protected] · www.vatec.de
PD-AELE-11-BEHRENS-GB.DOC
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item P1
Service Type: Description
Oil bil e um BS 50 Piston pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61363
80 1000 5,00 -0,50 3,00 3,50 1,50 1,90 1700
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Bronze G-CuSn10 Rolling contact grease S Ramie + PTFE DN G 2" G 1 1/2"
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump
Power supply Power Rated current Starting current
CSM 100L-4 IM B3, IP 55, ISO B DOL 440 / 60 2,60 4,87 32,60
PTC : SPM : no Space heater : no
Weights
/
32,00
Total
(kg)
: 32,00
16.02.2005
Operating Instructions
Spare Parts List
SPECK “ BÜFFEL” Pumps and Pump Units BS15, BS25, BS40, BS50 1. In General Every individual pump undergoes a lengthy test-run before leaving our factory. The pump units are approved by the German authorities for technical inspection (TÜV) as well as by the trade and industrial association and comply with EC guidelines for machinery construction. 1.1 Appl ication SPECK piston pumps are for pumping drinking-water and domestic water and find their use in: • Single & Multi-storey Houses • Agriculture/Farming • Shipping • Industry • Horticulture Standard piston pumps and pump units are not to be used for conveying any medium other than water, except if written consent is given by the manufacturer. Special versions are built by us for pumping other media. 1.2 Economy Speck piston pumps save energy. They only require 0.25 kW/h to pump 1 m 3 of water. The comparatively high price of a piston pump is rewarded in time by its low power consumption and long working life. 1.3 Accessories A belt-guard is available for V-belt drive. The law on technical appliances obligates the manufacturer to always supply a belt-guard, even for pumps without motors. Please note this when ordering. Declaration of Conformity
Declaration by the Manufacturer
We herewith declare on our own liability that the following pump units Pumps with Motor: BS15 BS25 BS40 BS50
that the following Pump units BS15/150L BS15/200L BS15/300L BS25/200L BS25/300L
Pumps without Motor: Pressure Tank Pressure Tank Pressure Tank Pressure Tank Pressure Tank
BS15 BS25 BS40 BS50
comply with pertinent stipulations as per: EC-Machine Guidelines 89/392/EWG Applied compatible standards: EN 809 EN 292 T1 EN 292 T2 Electromagnetic Compatibil ity: 89/336/EWG Applied compatible standards: EN50 081-1 EN50 082-2 Use of Electrical Equipment within specified Voltage Limits: 73/23/EWG Applied compatible standards: EN60 335-1 ppa. ........................................ EN60 335-2-51 (Technical Director)
Country of Origin: Federal Republic of Germany
S P E C K - K O L B E N P U M P E N FA B R I K Otto Speck GmbH & Co. KG · P.O.Box 1240 · D-82523 Geretsried Tel. (08171) 62930 · Telefax (08171) 629399 D1620 1 0799L
1
1.4 Technical Data and Dimension s “ Büffel” Piston Pump Model Flow Rate Water Head normal/maximum Motor Performance at 40m Motor Performance at 60m No. of V-Belts Profile x Inner Length Connection Sizes Suction x Discharge Dimensions approx. Weight w/o Motor approx.
BS15
BS25
BS40
BS50
l/h
1500
2500
4000
5000
m
40/60
40/60
40/60
40/60
kW
0,37
0,55
0,75
1,1
kW
0,55
0,75
1,1
1,5
2 10x820
2 13x975
2 13x1120
2 17x1335
Inch
1x1
1¼x1
1½x1¼
2x1½
cm kg
52x22x32 28
66x23x38 46
75x26x42 66
85x36x47 90
“Büffelpump”
Pump Units - Pump with Horizontal Tank Pump Model
Size of Tank
Connection Sizes Suct./Disch.
Flow Rate
(litre)
(inch)
(l/h)
BS15
150 200 300
1x1 1¼x1
1500
BS25
200 300
1¼x1
2500
Motor Performance (kW)
Dimensions (L x B x H)
Weight
6 bar
(approx. cm)
(approx. kg)
0,37
0,55
105 x 45 x 84 107 x 50 x 85 140 x 55 x 96
60 70
0,55
0,75
107 x 50x 100 140 x 55 x 110
105 110
4 bar
“Büffel“ Pump Unit
2
1.5 Spare Parts List Part No.
Description
1
Crankcase
1a 1b
BS15
BS25
BS40
BS50
Part No.
Description
BS15
BS25
BS40
BS50
01.0020 01.0148 01.0149 01.0142
18
Pump V-belt Pulley
19.0001 19.0014 19.0008 19.0049
Hexagon Screw
21.0290 21.0256 21.0125 21.0258
18a
Hexagon Screw w/Pointed Extension
21.0161
Stud Bolt
21.0147
21.0045
21.0154
18b
Motor V-Belt Pulley
19.0051 19.0050 19.0038 19.0009
1c
Hexagon Nut
07.3001
07.2398
07.0988
18c
Pointed Threaded Stud
21.0110 21.0113
21.0114
2
Gear Cover
03.0012 03.0025 03.0026 03.0027
19
Motor Mounting Rail left
23.0001
23.0018
23.0016
2a
Hexagon Screw
21.0256
192
Motor Mounting Rail right
23.0119
23.0018
23.0120
06.0440 06.0441 06.0442 06.0443
19a
Hinge Pin with Thread
11.0332
11.0331
11.0334
07.0614
19b
Hinge Pin
11.0235
11.0082
11.0335
21.0115
21.0120
2x
Gasket for Gear Cover
2b
Vent Plug
2xx
Gasket for 2b
21.0257
21.0258
06.0312
19c
Hexagon Screw
21.0116
3
Valve Casing Assy w/Stud Bolts + Nuts
00.2384 00.2385 00.2386 00.2387
19d
Insulation Sleeve
07.0161
07.0162
3a
Suction Flange
20.0031 20.0069 20.0062 20.0087
19e
Hexagon Nut
07.3001
07.2398
3b
Discharge Flange
191
Hexagon Screw
21.0290
21.0256
3c
Hexagon Screw
21.0062
21.0188 21.0253
Motor Rocker Assy
00.2442 00.2035 00.2443 00.2444
3x
Flange Gasket
06.0387
06.0400 06.0413
20/21
Diaphragm Safety Valve Assy w/Seat 4 bar
00.13 03
00.13 05
400
Gear Assy
00.2012 00.2013 00.2014 00.2015
20/21
Diaphragm Safety Valve Assy w/ Seat 6 bar
00.13 04
00.13 06
Air Chamber w/Safety Valve 4 bar + Filler Plug
00.23 96
00.23 97
00.24 00
00.24 01
20x
Gasket for Safety Valve Casing
Air Chamber w/Safety Valve 6 bar + Filler Plug
00.24 25
00.24 26
00.24 28
00.24 29
21
Safety Valve Seat Assy
20.0031
20.0032 20.0088
06.0395 00.3205
00.3208
06.0312
06.1020
5
Air Chamber w/o Safety Valve
01.0341 01.0232 01.0235 01.0237
21x
Gasket for No 21
5x
Air Chamber Gasket
06.0085 06.0086 06.0088 06.0089
22
Acorn Nut for Air Chamber
6
Stuffing Box Casing
01.0021 01.0233 01.0066 01.0534
22a
Air Chamber Stud Bolt
21.0044 21.0195 21.0042 21.0043
6a
Stuffing Box Screw
2 2b
Disc
0 7.1259
6b
Seal Ring
6c
Stuffing Box Insert
07.2875
07.1291
06.0403 -
-
07.0485
07.1257
07.0485
0 7.1211
07 .1259
06.0411 06.0419
23
Crosshead
17.0014 17.0015 17.0017 17.0002
07.1292 07.2226
23a
Crosshead Pin
11.0357 11.0358 11.0359 11.0360
24
6d
Gland Packing-Ring
06.1089
06.1136 06.1139
6f
Brass Disc
07.1286
07.1293 07.2227
6x
Stuffing Box Gasket
Oil Indicator with Nut Oil Level Gauge/Oil Dipstick
-
00.1953
00.1959
-
-
00.1938
06.0508 06.0509 06.0510 06.0220
24x
Gasket
Stuffing Box complete
00.2255 00.2256 00.2257 00.2258
25
Main Bearing Sleeve
05.0032 05.0033 05.0039 05.0034
Piston Rod Assy with Hexagon Nuts
00.2391 00.5414 00.2393 00.2394
26
Oil Splash Cap
03.0100 03.0118 03.0098 03.0167
7
Piston Rod
11.0232 11.0233 11.0029 11.0234
27
Oil Scraper
06.0408
06.0417 06.0470
7a
Hexagon Nut
28
Oil Filler Plug w/o Thread
07.0489
07.1319 07.1320
07.2398
07.0988 07.1738
7b
Reducing Ring for DUO-Piston
07.1933
8
DUO-Piston Simrit
06.0873 06.0872 06.0871 06.0877
8a
Hexagon Nut
9
Cylinder Assy
-
-
07.4083
-
29
-
06.0312
Snifting Valve G3/8 with Stop Screw
00.1939
Snifting Valve G3/8 with Hose Nipple
00.1940
07.4084 07.1944
29a
Snifting Valve Lip
06.0398
00.1916 00.1917 00.1918 00.1919
29x
Gasket for Snifting Valve
06.1020
9a
Hexagon Screw
21.0256
21.0258
30
Bearing Cover open
03.0185
03.0184
03.0028
9x
Cylinder Gasket
06.0777 06.0117 06.0525 06.0118
21.0257
30a
Bearing Cover closed
03.0013
03.0194
03.0182
10
Cylinder Cover
03.0014 03.0040 03.0144 03.0145
30b
Hexagon Screw
Hexagon Screw
21.0366
30x
Gasket for Bearing Cover
06.0447
10x
Gasket for Cylinder Cover
06.0589 06.0590 06.0591 06.0119
301
Radial Shaft Seal
06.0418
00.2170 00.2071 00.1291 00.2346
302
Grooved Ball Bearing
05.0111 05.0151 05.0110 05.0156
303
Spacer Ring
07.1302
304
Spacer Ring
07.1302 07.1307 07.1450 07.1540
304a
Woodruff Key
07.1200
11
Suction Valve Assy Suction Valve Stem
112
Suction Valve Seat (Brass)
118
Self-Locking Hexagon Nut
12
Discharge Valve Assy
121
Discharge Valve Stem
122
Discharge Valve Seat (Brass)
119/129
07.2539
07.1220
07.0021 07.0023 07.0065 07.1158 07.0669
-
-
00.2171 00.2072 00.1292 00.2347 07.2540
07.1219
07.0020 07.0022 07.2608 07.1157
Suction and Discharge Valve Retainer
113/123 Suction / Discharge Rubber Valve Plate
21.0366
21.0125
10a
111
21.0256
21.0315
07.2538
-
-
06.1065 06.1066 06.0857 06.0858
06.0448
06.0449
06.0399
06.0409
07.1307
07.1321
33
Plug
07.0751
07.2803
33x
Gasket
06.0312
06.1020
34
V-Belt
07.1303 07.1308 07.1312 07.1322
35
Main Bearing Shaft
11.0018 11.0019 11.0013 11.0014
35a
Cover for Main Bearing Shaft
03.0188 03.0189
114/124 Spring Tension Disc (large)
-
-
07.1939 07.1361
35b
Notched Nail
115/125 Valve Spring
-
-
07.3662 07.0025
35x
Gasket for Main Bearing Shaft
-
03.0190
-
07.1977
06.0746 06.0747
06.0436
116/126
Spring Tension Disc (small)
-
-
07.1360
405
Fitting Disc for Connecting Rod 0.5mm
07.1304
07.1313 07.1925
117/127
Cotter Pin
-
-
07.1215
405a
Fitting Disc for Cnnecting Rod 0.2mm
07.1305
07.1314 07.1924
11x/12x Gasket for Valve Seat
06.0391 06.0405 06.0416 06.0518
Complete Set of Gaskets
00.2453 00.2454 00.2455 00.2456
21.0002 21.0194 21.0046 21.0051
xx
Crankcase Assy
00.2753
Hexagon Nut
07.3001
Crankcase Assy, exchanged
00.2757 00.2758 00.2759 00.2760
Disc
07.2904
13
Valve Bridge Stud Bolt
13a 13b 14
Valve Brigde
15
Plug
07.0487
15x
Gasket
06.0054
Air Volume Control
00.2479
03.0268
07.2398 -
07.0988 -
-
00.2754 00.2755 00.2756
Pump Head Assy with Safety Valve 4bar 00.2617 00.2618 00.2619 00.2620
03.0042 03.0044
Pump Head Assy with Safety Valve 6bar 00.2745 00.2746 00.2747 00.2748
16
Plug
07.0487
Air Hose 0.9 m
32.0006
16x
Gasket
06.0054
Drain Cock G1/4
00.1941
Gasket for Drain Cock
06.0312
17
Connecting Rod Assy
17a
Tension Screw for Connecting Rod
17b
Sleeve for Connecting Rod
17c
Hexagon Nut
00.2004 00.2005 00.2006 00.2007 21.0103
21.0104 21.0105
05.0066 05.0067 05.0068 05.0069 07.2618
07.2022 07.1995
3
1.5.2 Exploded View N.B. The self-locking nut in the suction valve should only be used once.Please keep this in mind when ordering spare parts!
Valves BS15 / BS25
When ordering spare parts, please state item number and code number of the part required as well as the pump model and year of construction which can be found on the name plate.
2
2. Safety This Operation Manual gives basic instructions which are to be observed during installation, operation and maintenance of the pump. It is therefore imperative that this manual be read by the responsible personnel/operator prior to assembly and commissioning. It is always to be kept available at the installation site. It is not only the general safety instructions contained under this main heading `Safety` that are to be observed, but also the specific information provided under the other main headings. 2.1 Kennzeichnung von Hinweisen in der Betriebsanleitung Safety instructions given in this manual, non-compliance with which would affect safety, are identified by the following symbol: or where electrical safety is involved, with
see DIN 4844 - W9
see DIN 4844 - W8
Safety measures which can cause damage to the machine if not adhered to, are marked It is imperative that signs affixed to the machine, e.g. • •
arrow indicating the direction of rotation symbols indicating fluid connections
be observed and kept legible. 2.2 Qualification and Training of Operating Personnel The personnel responsible for operation, maintenance, inspection and assembly must be adequately qualified. Scope of responsibility and supervision of the personnel must be exactly defined by the plant operator. If the staff does not have the necessary knowledge, they must be trained and instructed, which may be performed by the machine manufacturer or supplier on behalf of the plant operator. Moreover, the plant operator is to make sure that the contents of the operating manual are fully understood by the personnel. 2.3 Hazards in the Event of Non-Compliance with the Safety Instructions. Non-compliance with the safety instructions may produce a risk to the personnel as well as to the environment and the machine, and may result in a loss of any right to claim damages. For example, non-compliance may involve the following hazards: Failure of important functions of the machine/plant Failure of specified procedures of maintenance and repair Exposure of people to electrical, mechanical and chemical hazards Endangering the environment owing to hazardous substances being released. • • • •
2.4 Safety at Wor k The safety instructions contained in this manual, the relevant national accident prevention regulations and any other service and safety instructions issued by the plant operator are to be observed. 2.5 Safety Instructions Relevant for Operation If hot or cold machine components involve hazards, they must be guarded against accidental contact. Guards for moving parts (e.g. coupling) must not be removed from the machine while in operation. Any leakage of hazardous (e.g. explosive, toxic, hot) fluids (e.g. from the shaft seal) must be drained away so as to prevent any risk to persons or the environment. Statutory regulations are to be complied with. Hazards resulting from electricity are to be prevented (see, for example, the VDE Specifications and the by-laws of the local power supply utilities). • • •
•
2.6 Safety Instructions Relevant for Maintenance, Inspection and Assembly Work It shall be the plant operator’s responsibility to ensure that all maintenance, inspection and assembly work is performed by authorized and qualified personnel who have adequately familiarized themselves with the subject matter by studying this manual in detail. Any work on the machine shall only be performed when it is at a standstill. Pumps and pump units which convey hazardous media must be decontaminated. On completion of work, all safety and protective facilities must be re-installed and made operative again. Prior to restarting the machine, the instructions listed under `Operation` are to be observed.
3
2.7 Unauthorized Alterations and Production of Spare Parts Any modification to the machine may only be made after consultation with the manufacturer. Using spare parts and accessories authorized by the manufacturer is in the interest of safety. Use of other parts may exempt the manufacturer from any liability. 2.8 Unauthori zed Modes of Operatio n
The reliability of the machine delivered will be only guaranteed if it is used in the manner intended, in accordance with clause 1 `In General` of this manual. The limit values specified in the data sheet must under no circumstances be exceeded. Pending Standards and other Data DIN4844 Part 1: Safety descriptions and safety signs W8 supplement sheet 13 DIN4844 Part 1: Safety descriptions and safety signs W9 supplement sheet 14
3. Transpor t and Storage Pumps and pump units must not be stored for any length of time in a humid place or where temperatures are below zero.The storage room should be airy as moisture will damage the motor and thus void the warranty. Pumps are packed for transportation in cardboard boxes or on pallets. When unpacking, check for damage.
4. Description 4.1 “Pumpmeister” SPECK piston pumps of the ‘’Büffel’’ pump series have a thoroughly proven double-helical precision gear of unsurpassed working quietness and service life. When turned in the correct direction, the gear is lubricated by an oil-dip bath with flooded crosshead. Suction and discharge connections are on the valve casing and are interchangeable. Valve casing, air chamber, stuffing box and cylinder cover are of grey cast iron (GG20). The brass suction and discharge valves (2 of each) are made easily accessible by removing the air chamber. The suction/discharge line does not have to be removed. The solid conrod is of bronze (G-CuSn10). The brass cylinder sleeve can be removed using set-screws. The duo-piston is of NBR rubber. Teflon-impregnated packing rings are used for the piston rod sealing in the stuffing box. A TÜV (German authorities for technical inspection) approved diaphragm safety valve protects against inadmissible excessive pressure. Water will not flow out of the pump if the pressure is too high. Surplus water is circulated within the pump, back t o the suction side. 4.2 “B üffelpumpe” Pump Unit SPECK pump units are ‘’Büffelpumpe’’ piston pumps on galvanized horizontal pressure tanks, complete systems ready for connection. They are equipped with an electric motor, V-belt pulleys, V-belts, belt-guard, automatic air volume control, pressure switch, pressure gauge and a built-in safety valve. The automatic air volume control installed in the pressure tank of the unit automatically ensures the correct ratio between water content and the necessary air cushion. If the horizontal tank is half full, the valve of the automatic air volume control, activated by the float, opens and the pump begins conveying both air and water into the tank. A suction head of approx. 4-6 m is required so that the pump can draw in air in the proper manner. When water leaves the tank, the pressure in the tank drops until the pressure eventually sinks to the automatic switchon point at which the pressure switch turns on the motor/pump. The amount of water which left the tank is then pumped in again until the switch-off level is attained. This procedure repeats itself again and again at irregular intervals, depending on how often and how much water is withdrawn from the tank. 4.3 Values for Pressure Switch Adj ustment Pump Unit 4 bar: Switch-On Pressure: 2 bar Switch-Off Pressure: 3.5 bar Pump Unit 6 bar Switch-On Pressure: 3 bar Switch-Off Pressure: 5.5 bar
4
5. Set-Up and Installation (onl y to be done by skilled workmen) 5.1 Pump Unit The complete pump unit with horizontal pressure tank is supplied ready-assembled. A special foundation is not necessary. The tank can be fixed to the foundation by 4 spacer blocks.
The room must be frost-proof and dry. It should also be well aired in order to prevent undesirable moisture condensate forming on the unit. Moisture damages the motor. To protect against accidents, each pump is to be equipped with a belt-guard which conforms to trade union and/or general safety rules. The pump-motor must be protected by a correctly adjusted motor protector.
„Büffel“ Pump Unit: Pump and motor, horizontal pressure tank and belt-guard
5.2 Pump Unit with Vertical Tank Assembly: Contrary to the complete TÜV-approved pump units with horizontal tanks which are supplied ready assemblied, the units with vertical tanks have to be set up and installed by a plumber on location. They function the same as the ready assembled units. However, we wish to point out that an automatic air volume control can also be installed in a vertical tank when the unit is being set up (s. fig. 113). Directions (D10671) for installing the automatic air volume control are available upon request.
Discharge Line
Suction Line Fig. 113 „Büffel“ pump unit with vertical tank
5
5.3 „ Büffel“ Pump Single ‘’Büffel’’ piston pumps are screwed on to a brick or concrete base and secured with foundation bolts. No particular foundation is required for vertical tanks. Pumps without a base plate and therefore without vibration insulation should be mounted on to a piece of anti-vibration material placed between the pump and ground.
Fig. 112 „Büffel“ pump
5.4 Suction Line for Pump Units and ‘’Büf fel’’ Pumps
Perfect functioning of the pump depends largely on well layed-out suction lines. In order to prevent airpockets, the suction line should rise gradually from the well to the pump, or should at least be layed horizontally. It must be absolutely seal proof and the inner diameter should at least be as large as the connection on the pump. Only bows are to be used, no elbows. It is advisable to install a foot valve or an intermediate valve in the case of a closed filter well. If suction lines are longer than 30 m, a suction air chamber is to be installed directly in front of the pump. If vertical tanks are used (fig. 113), it is advisable to support heavy suction lines so that their weight does not pull on the pump. 5.5 Suction Head
The total gauged suction head which is the height between the water level and the pump plus loss of friction in the pipe and possible filter resistance, is not to exceed 7.5 m, not forgetting that in dry seasons the water level in the well may be lower than usual. In the case of short suction lines or a suction head of below 2m, or if input pressure is present, a shut-off valve (not a tilted seat-valve) must be installed in front of the pump. This shut-off valve can be adjusted with greater accuracy to the required suction head, ensuring the avoidance of water-hammer. 5.6 Intake Pressure - Pump Unit as Bo oster Set
If the inlet pressure is more than 0.3 bar (3 m), it is advisable to install a pressure-free tank with float valve. If this cannot be done, a shut-off regulator valve must under all circumstances be installed in the feed line. A vacuum of 4-6 m has to be provided if the automatic air volume control is to function properly. If the pump hammers, install a suction air chamber (approx. 7.5-15 ltrs) in the feed line. A shut-off valve is at all events necessary in a suction line with intake pressure so the pump can be opened for servicing. 5.7 Discharge Line - Refers only to inst allation of pump unit s wit h vertical tanks or p umps alone
If possible, the line should rise gradually upwards from the pump to the tank or at least be horizontal - it should never slope downwards. Only use curved joints, elbows may only be used after the tank. 5.8 Umtausch der Saug- und Druckanschlüsse (Does not apply to units with horizontal tanks) The suction and discharge sides of SPECK ‘’Büffel’’ pumps can be interchanged by converting the suction and discharge valves. This often saves inconvenient installation of suction and discharge lines. Install clean valve seals and make sure the valves sit properly.
Fig. 114
6
Af ter su ct io n and dis ch arge valves have been exchnged, the air chamber must be turned around 180° so that the safety valve is always located on the discharge side.
6. Operation 6.1 To Fill Pump with Oil
Fill crankcase with SAE30 oil through opening above crosshead (23). BS15
BS25
BS40
BS50
0,2 litres
0,3 litres
0,8 litres
1,0 litres
6.2 To Fill Pump
Fill up pump head with water, pouring the water in via filler plug (33) and at the same time turning the pump V-belt pulley (18) manually in the direction of the arrow. In the case of long suction lines, fill right up to the foot valve/intermediate valve (see 5.4) 6.3 To Close Fittings Close fittings in discharge line after the tank or turn off all drain taps. 6.4 Motor Al ignment and Electrical Connection Using a ruler, make sure the pump and motor V-belt pulleys (18/18b) are in line with each other. The motor could have been shifted during transport and if the pulleys do not align precisely, the belts will wear out quickly.
Connect the electric motor as per the circuit diagram to be found in the terminal box of the motor. This work is to be carried out by appropriately qualified personnel only. 6.5 To Switch on Motor
Check the revolving direction and reverse polarity if the motor is running in the wrong direction. The pump starts pumping. This can be seen at the suction supports (111/II) through the transparent hose. Depending on the size of the tank, it takes 5-15 minutes to fill and for the pressure switch to switch off at 3.5/5.5 bar. The pump firstly vents the suction line and then pumps a water/air mixture which can be seen clearly through a transparent hose. The air bubbles in the suction line should disappear after a while, otherwise there is reason to believe the suction line is not seal-proof. 6.6 To Let Water Out Turn tap on and let water out. Pressure drops to 2 or 3 bar respectively and the pump switches on again automatically. Approximately 2000 litres of water per hour flow out of an open G1/2’’ tap at 3 bar pressure. 6.7 On/Off Switching Pressure (for 4 and 6 bar units)
The construction of the pump and built-in safety valve have been approved by the German authorities for technical inspection (TÜV). The safety valve is adjusted to 4 or 6 bar in accordance with TÜV regulations. The pressure tank is also approved for max. pressure of 4 or 6 bar. The pressure switch is therefore to be set to a max. switch-off pressure not higher than 3.5 bar / 5.5 bar, otherwise the safety valve will be activated. To readjust switch-on / switch-off pressure see instructions in pressure switch (fig. 111/IV). Switching Stages: 4 bar Pump Unit 6 bar Pump Unit
Switch-On Pressure Switch-Off Pressure Switch-On Pressure Switch-Off Pressure
2 bar 3,5 bar 3 bar 5,5 bar
Suction Line
Discharge Line Fig. 111 Büffel Pump Unit
7
7. Maintenance and Servicing 7.1 Lubr ication
The gear is lubricated automatically provided the pump revolves in the correct direction. Oil level should be checked every three months and topped up if necessary till oil can be seen through the indicator glass (24). First oil change after 3 months operation and then every 2 years, or every 6 months if the pump is running continuously. This is done by unscrewing the indicator (24) or screw (16) and draining out the old oil. Clean out the crankcase thereafter (removing gear cover [2]) and refill with fresh oil as described under paragraph 6.1. 7.2 Stuffing B ox
The compact stuffing box is made of Teflon-impregnated packing rings and a seal ring and requires practically no maintenance at all. If the stuffing box should drip, tighten stuffing box nut (6a) carefully by approx. one 1/2 turn. If this does not help, the whole stuffing box (6d) must be replaced. In this case, the seal ring (6b) should also be changed. Pay careful attention when installing seal ring: the lip ring spring must face the piston. 7.3 V-Belts
V-belt (34) should not be overtensioned. However, it is advisable to tighten belts up again after a few days of operation. When renewing V-belts on multi-belt drive, the complete set has to be replaced. 7.4 Gear
The original SPECK high pressure ‘’Büffel’’ pump has a double-herringbone (helical) precision gear with a bronze connecting rod. If the directions under paragraph 7.1 for lubrication are followed, further maintenance is practically unnecessary. Only the connecting rod alone might need readjusting after approx. 1 year when it has been run in and if a possible knocking sound can be heard. To do this, unscrew self-locking hexagon nut (17c), screw out inner hexagon tension screw and remove 0.1 - 0.5 mm of spacer shims (405) as required from connecting rod joint. Screw back tension screw (17a) tightly against hexagon nut. After approx. 1 hour of operation, check whether the connecting rod has not been overadjusted and is running hot.
Abb. 115 Crosssectional Diagramm of Casing
7.5 Air Replenishment - for Cold Water Operation Only
The pump will run smoothly and silently if there is air in the air chamber. This air cushion is regulated via the snifting valve. At the same time air is pumped into the pressure tank. The more air there is in the pressure tank, the more water can be discharged before the pump switches on again (see paragraph 4.2). If the automatic air volume control has to be repaired, kindly ask for our instruction sheet D10672. The unit itself is only available as a complete set. 8
8. Failures and Remedies If you have trouble with your pump, you may be able to help yourself by reading the tips we give you below. If you cannot find the reason for the trouble, call a plumber or write to us, not forgetting to mention the pump model and its serial number. Prior to doi ng any work on th e pump, switch off t he electricit y and make sure that the pump is idle and the pressure at zero. 8.1 Little or no water at all is being pumped Possibl e Reason
Remedy
a) Pump is running but delivers no water even though it is filled properly.
Remove air chamber (5) and loosen rubber valve discs (113/123) which have probably got stuck if the pump has been stored for a long time.
b) Not sufficient water in the pump.
Refill pump as explained in 6.2 and at the same time turn the pump several times pouring in water little by little till there are 2-4 litres in the pump. Screw on filler plug (33) again and seal carefully. More water may be necessary if the suction line is very long or the suction head very high.
c) Suction head too high / suction line too long.
Measure difference between water level and pump flange connection (fig. 111/I). Compare loss of friction in long pipes with table (available upon request) and add the difference in height.
d) Suction line is not seal-proof.
After the pump has been running for a while, check whether air bubbles can be seen through transparent hose (Fig. 111/II) above elbow on tank. If so, press out air, find leak and make it seal-proof.
e) Soiled or worn-out valves
Pebbles, hemp, shavings etc. coming from new wells often get absorbed into the pump so the air chamber (5) has to be removed and the valves checked. Loosen nuts above valve bridge. Remove valve bridge and any crust which may be on it. Valves are not screwed in. If they are stuck, press them loose with the handle of a hammer. The valve seat seal is under the valve - make sure that the seat is clean. Rubber valve discs (113/123) may have to be replaced if the pump is old.
f) Stuffing box is not seal-proof.
Tighten up nut (6a) a little. If this does not help, replace packing rings (6d) and possibly seal rings (6b) as well. Do not use hemp, we use Teflon-impregnated packing rings.
8.2 Pump Knocks Possibl e Reason
Remedy
a) There is no air cushion in the air chamber
Make sure that the air volume control (Fig.111/III) is working properly. The snifting valve should hiss when the pump is running. Check whether rubber lip (29a) is dirty or clogged. Air could be escaping through screw on filler plug, therefore check by covering sealing surfaces of air chamber and filler plug with a soap solution.
b) Pre-pressure in pump
Water level in pump/air chamber is too high because snifting valve has not absorbed enough air. Install regulator in suction line (s.5.5/5.6). Pump should run with about 5 metre vacuum ensuring that sufficient air is pumped.
c) Pump suction head is very low
Same applies here as explained under b). A vacuum must be provided by means of a regulator so that sufficient air will be pumped.
d) High suction head - long suction line
Install a suction air chamber as per 5.4 and ensure sufficient ventilation. Make sure there is enough water in the well, e.g. after a dry season.
e) Conrod bearings in pump deflect
You can not always determine the reason for knocking by ear, so you have to turn the Vbelt pulley (18) backwards and forwards to determine any clearance between bearing and conrod. Repairs to the gear are be st done by a skilled tradesman.
f) The pump V-belt pulley deflects and does not sit properly on the crankshaft
As described under e).
g) One of the ball bearings is defective
As described under e).
8.3 Pump swi tches on when very litt le water is discharged and switches off i mmediately the tap is tur ned off Possibl e Reason
Remedy
The air cushion is not filled up sufficiently. During initial operation, there may not have been enough air pumped into the tank or the air the pump has pumped into the tank is escaping somewhere (pressure switch, pressure gauge, air volume control, pump connections, transport damage).
If snifting valve and air volume control are working properly (111/III) and there still is not enough air in the tank, coat all threaded connections on tank with a soap solution to determine where it is leaking. It could also be that the pressure switch (111/IV) is not airtight.
9
8.4 Pump switches on automatically although taps are turned off Possibl e Reason
Remedy
a) A tap is leaking or air is escaping from the tank.
Check by switching off the complete unit overnight. Turn off all taps and check whether the pressure drops.
b) Leaky valves or leaky safety valve cause water to run back into the well.
Open pump and check whether the valves are sealing properly.
c) Foot valve/intermediate valve in the suction line leaks. Water runs back into the well.
Switch pump off and lift safety valve at 3.5/5.5 bar. If foot valve/intermediate valve is working properly, no return flow should be heard (or seen at pressure gauge of tank) immediately after lever (214) has been lifted.
8.5 Air escapes from tap when water is l et out Possibl e Reason
Remedy
a) There is too much air in the tank. The well water is probably very gassy and a lot of air separates into the tank. If the suction line is very long and the suction head high, it could be that too much air is being pumped.
In this case, it is advisable to disconnect the pipe of the air volume control for a while or install a special rubber lip with a very small hole into the snifting valve.
b) Suction line leaks.
Find leak and seal it.
8.6 Water is pumped easily t ill s hortly before switch-off pr essure is reached and then the pump continues to run but does not pump any water because it can’t r each th e final pressure Possibl e Reason
Remedy
This can happen if too much air is pumped through the air volume control when suction lines are very long and suction head very high. This often occurs when the suction line is not absolutely seal-proof and allows even more air to get into the pump. It can also be caused by worn out rubber valve plates, worn out cylinder or pistons.
We recommend either installing a rubber lip with a very small hole or put the air volume control in the suction line out of action from time to time. Replace rubber valve plates (113/123). Check whether piston or brass cylinder are worn out and replace as necessary.
8.7 Water leaks at Ai r Volume Control Possibl e Reason
Remedy
Rubber lip of snifting valve (29) is damaged.
Replace rubber lip (29a).
Suction Line
Discharge Line Fig. 111 „Büffel“ Pump Unit
10
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item P2
Service Type: Description
Slud e um PL 300 Rotary lobe pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61364
100 950 50,00 -0,50 3,50 4,00 7,00 10,00 1750 2,00
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 cast iron-NBR Steel Rolling contact grease Mechanical seal DuronitV DN 125 125
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
SK42-160M-4 , IP 55, ISO B DOL 440 / 60 15,00 29,00 173,00
PTC : SPM : no Space heater : no
Weights
/
Total
(kg)
:
16.02.2005
PLSeries
BÖRGER GmbH, Germany
www.boerger.de
Tel: +49 (0)2862 9103-20
Operating and Maintenance Manual Table of Contents BÖRGER – Rotary Lobe Pumps Models PL 100, PL 200, PL 300, PL 400 1.
BÖRGER ROTARY LO LOBE PU PUMPS (BARE SHAFT PUMP) ............... ....................... ............... ............... ............3 ....3 1.1 1.2 1.3 1.4
2.
CONSTRUCTION OF THE ROTARY LOBE PUMP..............................................................3 FLANGES ..................................................................................................................4 DRIVE SPECIFICATION ................................................................................................4 ASSEMBLY OF AGGREGATE ........................................................................................4
COMPLE COMPLETE TE BÖRGER BÖRGER – AGGREG AGGREGATE ATE ....... ........... ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........5 ....5 2.1 STANDARD DESIGN ...................................................................................................5 2.2 LUBRICANT LEVEL AND CHANGE ................................................................................6
3.
INSTAL INSTALLAT LATION ION IN THE PROCESS PROCESS SYSTEM SYSTEM ......... ............. ....... ....... ........ ....... ....... ........ ........ ....... ....... ........ ........ ....... ....... .....8 .8
4.
START START UP ................ ....................... ............... ............... ............... ................ ............... ............... ............... ............... ................ ............... ............... ................ ...........9 ...9
5.
MAINTE MAINTENA NANCE NCE AND CONTRO CONTROL L ....... ........... ........ ........ ....... ....... ........ ........ ........ ....... ....... ........ ........ ........ ........ ....... ....... ........ ........ .......10 ...10 5.1 DISASSEMBLY OF QUICK RELEASE COVER AND FLANGES .........................................10 5.2 CLEANING OF THE ROTARY LOBE PUMP ...................................................................10 5.3 D ANGER OF FROST ..................................................................................................10
6.
TROUBLES TROUBLESHOOTI HOOTING.... NG............ ................ ............... ............... ................ ............... ............... ................ ............... ............... ................ ................ .........11 .11 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9
7.
PROBLEM / HELP .....................................................................................................11 CHANGING THE PISTON TYPE PL ..............................................................................13 READJUSTMENT OF ROTARY LOBES ..........................................................................15 EXCHANGE OF MECHANICAL SEAL ............................................................................16 EXCHANGE OF MIP R ADIAL LINERS ..........................................................................17 ADJUSTMENT OF THE AXIAL TOLERANCE OF THE ROTORS .........................................18 GLAND P ACKING .....................................................................................................18 SPECIAL PUMP CONSTRUCTIONS .............................................................................18 SPARE PARTS LIST ..................................................................................................19
SPARE SPARE PAR PARTS TS REGA REGARD RDING ING THE THE CODE CODE NU NUMBE MBER R ....... ........... ....... ....... ........ ........ ........ ....... ....... ........ ........ .......20 ...20 7.1 CODE NUMBER ........................................................................................................20 7.2 SPARE P ARTS LIST ..................................................................................................20
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1.
BÖRG BÖRGER ER Rot Rotary ary Lobe Lobe Pump Pump (Bar (Bare e Shaf Shaftt Pum Pump) p)
1.1 1.1
Cons Constr truc ucti tion on of the the Rot Rotar ary y Lobe Lobe Pump Pump
BOERGER Rotary Lobe Pumps of the PL Series are designed on a modular basis. Gear unit, axial wear plates, cover and mechanical seals remain the same throughout the series. The material of the fluid wetted parts of the pump unit should be adapted to the chemical and physical conditions of the fluid. The Code Number represents the parts used in the pump unit.
O i l F i l l B r e a t he he r Timing Gear
Safety Opening do not close Oil Fill Up Intermediate Chamber
Oil Gauge
Driving Schaft (top or bottom) Quick Release Cover Oil Drain R 1/2" Timing Gear
Oil Drain R1/2" Intermediate Chamber
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1.2
Flanges
The flange material is usually galvanized steel or stainless steel. Gaskets (see 7.2 Spare Parts List Pos. 25) have to be installed between between the pump casing and the flanges. The material of the Gaskets should be adapted to the chemical and physical conditions of the fluid.
Intermediate Chamber
Timing Gear
1.3
Pump Chamber
Drive Specification
The BOERGER Rotary Lobe Pump needs a drive unit with suitable rotation speed and torque. The design of the drive unit (rotation speed and power) depends on the hydraulic conditions (i.e. capacity, pressure, viscosity) of the application.
1.4
Assembly of Aggregate
The Rotary Lobe Pump and the drive unit must be assembled free of distortion. The pump shaft and drive shaft have to t o be connected with a suitable coupling including including guard for protection. After assembly of the pump aggregate aggregate on the foundation foundation and in the pipe pipe system the alignment alignment of the coupling has to be controlled as part of the warranty. Follow also Operation and Maintenance Manual of Drive Unit! Shaft Diameter of PL-Series: Shaft-Design Stan Standa dard rd,, DIN DIN 748 748 PTO – Profile
Diameter 35 mm (1,3 (1,38 8 “) 1 3/8“
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2.
Complete BÖRGER – Aggregate
2.1
Standard De Design
Rotary Lobe Pump and drive (standard: helical geared motor) fitted on common base (twist-free), made from galvanized steel, incl. elastic coupling and coupling guard. Also possible is an overhead mounted drive and a mechanically adjustable variable speed drive (VSD) for operation in a wide range of flow. The base of the aggregate has to be fastened on an even foundation. 1.)
BÖRGER Rotary Lobe Pump
2.)
Elastic coupling
3.)
Coupling Guard
4.)
V-Belt Disc
5.)
V-Belt
6.)
V-Belt Guard
7.)
Motor
8.)
Gear Reduction Unit
9.)
Variable Speed Drive
10.)
Base
11.)
Flanges
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2.2
Lubri ubric cant ant Leve Levell and and Chan Chang ge
Before start up of the pump unit check oil level of timing gear at the oil gauge. The oil level must be at the middle of the oil gauge. The oil of the timing gear and the fluid of the of intermediate chamber has to be exchanged every two years or after 10.000 hours of operation. The fluid level in the intermediate chamber must be at the level of the top shaft. The top opening of the intermediate chamber must remain open to the environment and must be protected against dirt with our plastic stopper. Submersible units must be equipped with a sensor for monitoring of the mechanical seal. The functions of the intermediate chamber are 1. Lubrication and and cooling cooling of the mechanical mechanical seals seals and rotor/shaft rotor/shaft connection connection 2. Detection of seal failures 3. Buffer zone zone to the sealed sealed timing gear Check fluid of intermediate chamber with every rotor change. When changing mechanical seals the intermediate chamber has to be flushed and cleaned with water before fill up of new fluid. Change the hydraulic oil at least every two years or after 10,000 operation hours. Consider that atmospheric conditions (temperature, humidity, aggressiveness etc.) can change the interval of oil-changes. oil-changes. Attention:
Please check if the factory site filled lubricant types and/or listed oil types of the pump unit are allowable with the t he environmental regulations at the application site. If need please consult factory.
Oil quantity depending on model! Rotary Lobe Pump Model PL 100 PL 200 PL 300 PL 400
Timing Gear Oil quantity App. 1,5 liter App. 1,5 liter App. 1,5 liter App. 1,5 liter
Intermediate Chamber Lubricant quantity App. 0,8 liter App. 0,8 liter App. 0,8 liter App. 0,8 liter
Factory site used oil types: Timing Gear: Inte Interrmedi media ate Cham hamber ber:
Mobilgear 630 MOBIL OBIL AMBREX 68
Attached is a list of factory factory approved lubricant lubricant types for BÖRGER BÖRGER Rotary Lobe Lobe Pumps:
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Oil Types Timing Gear Type of lubricant Minera Oil
AmbientTemperature -5...40 (normal)
Viskosity
ARAL
BP
CASTROL
DEA
ESSO
KLüber
MOBIL
SHELL
TRIPOL
ISO VG 220
Degol BG 220
Energol GRXP220
Alpha SP 220 Alpha MW 220 Alpha SP 100 Alpha MW 100 Hyspin AWS 15 Hyspin SP 15
Deagear DX SAE 85 W 90 Falcon CLP 150 Deagear DX SAE 80W Falcon CLP 150 Airkraft Hydraulic Oil 15
Spartan EP 220
Klüberoil GEM 1-220
Mobilgear 630
Shell Omala Oel 220
Tribol 1100/220
Spartan EP 100
Klüberoil GEM 1-100
Mobilgear 629
Shell Omala Oel 100
Tribol 1100/100
Univ Univis is J13 J13
Isofl Isoflex ex MT 30 rot
Mobil DTE 11M
Shell Tellus Oel T15
Tripol 770
Minera Oil
-15 25 25
ISO VG 100
Degol BG 100
Energol GR-XP 100
Minera Oil
-50...-15
ISO VG 15
Vitamol 1010
Bartran HV15
Lubricant Type Intermediate Chamber Type of lubricant Mineral Oil
AmbientTemperature -15 -15...+ ...+4 40
Viskosity
ARAL
BP
CASTROL
DEA
ESSO
KLüber
MOBIL
SHELL
TRIPOL
ISO ISO VG 68
Motanol HE 68
Energol CS 68
Magna 68
Renolin DTA 68
NURAY 68 68
Klüb er eroil GI GIM 1-68
AMBREX 68
SHELL Vitrea 68
Tripol 943 AW-68
Or alternative a mixture of Glysantine and water.
Atte Attent ntio ion: n:
Oil Oil leve levell mus mustt be be at at the the mid middl dle e of of the the oil oil gaug gauge e
Oil level and oil change for drive follow instruction of Operation and Maintenance Manual of the drive unit.
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3.
Installation in the Process System
The BÖRGER Rotary Lobe Pumps are self-priming under certain conditions. To prevent cavitation install the pump with flooded suction or only with a small suction lift. With larger suction lifts and/or long suction pipes, control that the NPSH available of the system is higher in comparison to the required NPSH of the pump. The required NSPH value must be at least a 0,5 m under the NPSH available to prevent cavitation. With suction lifts over 2 m it is required to install a check valve at a suitable position in the pipe system. Especially in pump installations with gaseous fluids it is important to prevent air bubbles on the suction side of the pump. If this is not practicable, install an air release valve close to the pump at a suitable position in the pipe system. This ensures a trouble free start up of the pump aggregate. Install compensators (follow the mounting instruction of the compensator manufacturer) between pump flanges and system especially with thin-walled pipes. Also consider loads caused by changing physical conditions (i.e. temperature). Connection flanges or valves are not allowed to load the pump unit. Before start up check and if needed correct the alignment of the coupling. Uneven foundation surfaces have to be corrected.
Recommended Maintenance Space
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4.
Start Up
•
Check the lubricant Levels (see 2.2)
•
Check that the flange and pipe connections are sealed and not leaking.
•
•
•
•
•
•
At pumps with infinite variable rotating flanges (i.e. mobile pumps) check the tightness of the clamps. Also check the quick connection flanges. Check all installed appurtenances in addition to the pump aggregate (i.e. VFDs, dry running protection, pressure gauges etc.). Check the rotation direction of the drive.
Prevent longer dry running in the start up phase. Fluid is needed for cooling of the pump. Do not operate pump in hose systems without supervision! The BÖRGER Rotary Lobe Pump can operate in either direction. Check if rotation direction fits your needs.
Top shaft rotates counterclockwise. Fluid flows in direction of arrow.
Top shaft rotates clockwise. Fluid flows in direction of arrow.
Change rotation direction of the drive or change to the other driving shaft of the pump (if suitable) to reverse flow. Opening of valves. •
•
After a short time the Rotary Lobe Pump is displacing the nominal capacity. The pressure is not allowed to rise over the permissible pressure of the pipe system and of the Rotary Lobe Pump and shall not overload the drive unit.
The top opening of the intermediate chamber must remain open to the environment and must be closed for dirt protection with our plastic stopper . The closing oft he top opening cause damages on the gear wheels and the bearings Datei: BEDI-PL-1-08-01-E-0, Stand:25.10.01
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5.
Maintenance and Control
Before every start up check lubricant levels. In addition to, the Lubricant has to be changed in the named periods. (see 2.2).
5.1 Disassembly of Quick Release Cover and Flanges Following are precautions before disassembly of quick release cover and flanges: •
Disconnect motor from power or remove drive from pump unit.
•
Close suction and discharge valves.
•
Loosen ring nuts of the quick release cover equally app. 5 mm and move the cover slowly of the pump casing. Pressure may still exist inside the pump.
Caution:
5.2
Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag.
Cleaning of the Rotary Lobe Pump
Remove quick release cover of the pump (see 5.1). Clean pump and flanges with suitable cleaning agent. Let the pump casing dry and use metal surface protection (i.e. grease) suitable for the rubber material of the rotors. Do not use grease with EPDM or SBR rotors.
5.3
Danger of Frost
The pump and pipe system must be secured against frost. As a supplement BOERGER can deliver a heated quick release cover.
Attention:
Frozen fluid pieces from the pipe system can cause wear inside the pump, especially at the rubber - coating of the rotors.
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6.
Troubleshooting
6.1
Problem / Help
Pump does not start after shut down Possible problem Help Solids have settled inside the pump after Cleaning of pump (see 5.2) shut down. •
•
•
•
•
•
Rotors are swollen and are tight to the pump casing.
•
Long fibers, foil or plastics are blocking the pump. Axial rotor tolerance misaligned Power and/or torque too weak, drive too small
•
Check temperature and chemical compounds of fluid. Change rotor to a suitable material. Cleaning of pump and suction flange (see 5.1), plan the installation of a MultiChopper
•
Adjust axial rotor tolerance (see 6.6)
•
Change to bigger drive
Pump does not self prime Possible problem Wrong direction of rotation
Help Change rotation direction of the drive
•
•
•
Suction pipe blocked
•
•
Suction connection leaky
•
•
Air bubble inside the pump or pipe system
•
•
Rubber coating of rotors destroyed
•
Clean of suction pipe Check gaskets and tightness of connections Fill up pump with fluid or release air out of the system Replace rotors; check temperature and chemical compounds of fluid. Change rotor to a suitable material.
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Pump cavitates Possible Problem Rotation speed too high: The cavities inside the pump are not filled (cavitation). •
•
Solid is blocking suction side
Help Decrease rotation speed and/or increase suction - pressure
•
•
Remove solid
Oil leakage at the top of the intermediate chamber Possible Problem O-rings of the mechanical seal are damaged •
Help Replace the o-rings of the mechanical seal (see 6.4; 6.6)
•
• •
Change of mechanical seal (see 6.4; 6.6)
Mechanical seal defect
Technical information mechanical seal
The single acting mechanical seals used in BOERGER Rotary Lobe Pumps consist of each two seal faces positioned against each other. The mechanical seals are quenched with the fluid (standard: hydraulic oil) in the intermediate chamber. With capillary and centrifugal force created by the rotation the oil is forced between the seal faces and lubricates the seal gap and removes developing heat from the mechanical seal. Pumped fluid is not needed to lubricate and/or cool the mechanical seal.
If the mechanical seals had to be opened during maintenance it is recommended to exchange the mechanical seal, even if the wear limit has not been reached.
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6.2
Changing the piston type PL
a) Switch off the pump and lock the drive unit. Seal off the suction and pressure pipes using the shut-off valves. (see 5.1) b) Uniformly unscrew the four ring nuts (1) by 5 mm and slide the lid (2) back a little to allow any pressure to get rid of.
Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. c) Unscrew the haxagon socket screws (3) of the two pistons using a 14 mm hexagon socket key. (Shafts can be retained by clamping with a part which has no sharp edges). d) Pull off the seal washer (4) in case they are existent. e) Unscrew the grub screws from the threaded bores (6), screw the piston withdrawal tool (see: 7. Spare parts list, item no. 90-91) into the threaded bores (6) and pull off the piston. f)
Check (if necessary replace) and oil the O-rings (5) and (7).
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g) Oil the shafts and slide on the new pistons. If several pistons have to be pushed on the shaft the sealing shell [8] with the two o-rings [check damages!] must be provided. Screw the grub screws back into the threaded bores (6) of the front pistons.
Note:
Check the quality symbol on the front sides of the old and new pistons.
h) Unscrew the two screws (3) again and slide on the sealing washer (4). i)
Screw in the cylinder screw (3) and tighten with a torque wrench: •
Torque: 180 Nm for standard screws, 8.8
•
Torque: 180 Nm for stainless steel screws, A4
j)
Turn the piston by hand and check for easy running.
k)
Replace the lid (2) and tighten the ring nuts (1).
l) Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump.
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6.3
Readjustment of Rotary Lobes (Optional Feature)
A A
A
a) Shut down pump unit and close valves surrounding the pump (see 5.1) b) Loosen ring nuts of the quick release cover equally app. 5 mm and move the cover slowly of the pump casing. Pressure may still exist inside the pump. Clean or flush the pump casing
Caution: Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag. c)
The rotors may only be readjusted when being positioned as shown in the above illustration. Turn the shafts until the rotors are in a vertical and horizontal position.
d) At the marked points carefully drill holes with a 10 mm twist drill through the rubber coating until you reach the socket head cap screw for adjustment. e) Readjust the rotors by turning the socket head cap screw until the sealing line between rotor radius and pump casing is readjusted to a tolerance of 0 – 0,1 mm. Use a thickness gage for checking the tolerances. During and after readjustment check easy movement of the rotors.
Attention: No possibility of reversing the adjustment! f)
Control the cover O-ring and tighten the quick release cover with the wear plate to the pump casing with the ring nuts.
g) Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump. Datei: BEDI-PL-1-08-01-E-0, Stand:25.10.01
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6.4
Exchange of Mechanical Seal
a)
Drain the lubricant from the intermediate chamber through the lubricant drain (11).
b)
Remove the rotors as described under 6.2.
c)
Remove the feather key (9) from the groove. Unscrew the holding bush with thread (2) by using the special BÖRGER tool (spare part list Pos. 95).
d)
Remove the mechanical seal rings (4) with O–rings (5) from the holding bush with thread (2) and from the stationary holding bush (8). Clean and oil the O-ring seats of the holding bushes. Flush the intermediate chamber for cleaning purpose.
e)
Push the O–rings (5) onto the new mechanical seal rings (4). Press one seal ring (4) into the stationary bush (8) and the other into the holding bush with thread (2).
f)
Screw the holding bush with thread (2) onto the shaft until aligned with the wear plate (7), then turn it backwards app. 1/6 revolution. The holding bush projects app. 0,3 mm to the wear plate. Ensure that one groove of the bush (2) is aligned with the groove on the shaft for the feather key (see 7.2).
g)
Place the feather key (9) into the aligned grooves of the holding bush with thread (2) and of the shaft.
h)
Check (replace if necessary) and oil the O–ring (1). Clean and oil the counter surfaces for the rotors.
i)
Refit the rotors (see 6.2)
j)
Fill fluid into the intermediate chamber through the oil inlet opening (10) (minimum to the level of the top shaft). Close intermediate chamber with plastic stopper for dirt protection.
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6.5
1.
Exchange of MIP Radial Liners (Optional Feature)
Disassembly of MIP Radial Liners a) Shut down pump unit and close valves surrounding the pump (see 5.1). b) Loosen ring nuts (3) of the quick release cover equally app. 1/5” and move the cover (4) slowly of the pump casing. Pressure may still exist inside the pump. Clean or flush the pump casing.
Caution:
Remaining pressure in the pump can splash fluid out of the gap between pump casing and cover. Cover gap with suitable rag.
c) Remove the axial wear plate (5). d) Now open the clamps (2) holding the MIP Radial Liners (6) in position by loosening the screws (1).
Attention: Check the CU–Rings and replace them if necessary. e) The MIP Radial Liners (6) can now be removed.
2.
Assembly of MIP Radial Liners a) Clean the pump casing from any particles. b) Push the MIP Radial Liners (6) into the pump casing symmetrically. c) Now fasten the MIP Radial Liners (6) by equally alternate tightening of the clamps (2). Observe an equal tolerance at both sides of the flange openings. d) Check easy motion of the rotors, if necessary, correct the alignment of the MIP Radial Liners. e) Control the cover O-ring and tighten the quick release cover with the wear plate to the pump casing with the ring nuts. f) Before restarting the pump, test it by carefully tipping the motor switch to ensure the function of the pump.
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6.6
Adjustment of the axial Tolerance of the Rotors
1.
Remove the lobes as described under 6.2.
2.
Take the feather key (9) out of the shaft groove.
3.
a)
The rotors are too tight to the quick release cover : Turn the holding bush with thread (2) clockwise 1/6 revolution until the next groove is aligned with the shaft groove by using the special BÖRGER tool.
b)
The rotors are too tight to the rear wear plate (7) : Turn the holding bush with thread (2) counter clockwise 1/6 revolution until the next groove is aligned with the shaft groove by using the special BÖRGER tool.
Do not unscrew the threaded bush (2) more than 1/6 turn! Danger of fluid leakage from the intermediate chamber! 4.
Place the feather key (9) into the aligned grooves of the holding bush with thread (2) and of the shaft.
5.
Refit the rotors (see 6.2).
6.7
Gland Packing
Please refer to separate operation and maintenance instructions.
6.8
Special Pump Constructions
Please refer to separate operation and maintenance instructions.
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6.9
Spare Parts List
The Spare Parts List contains position numbers referring to the explosion drawing, the name of the part, material, article number (important for spare part orders) and quantity per pump. The BÖRGER Rotary lobe pump is furnished with fluid wetted parts according to the code number (see 7.1).
Exchange of Rotary Lobes 2/4/6/8x 2/4x 0/4/8/12 x
rotor O-ring; 54 x 4 O-ring; 55 x 3
Pos. No.: Pos. No.: Pos. No.:
9 31 34
Pos. No.: Pos. No.: Pos. No.: Pos. No.:
15 31 33 34
Pos. No.: Pos. No.: Pos. No.: Pos. No.: Pos. No.: Pos. No.: Pos. No.:
10 11 12.1 30 31 34 52
Exchange of Mechanical Seal 2x 2x 2x 0/4/8/12 x
mechanical seal O–ring 54 x 4 O–ring 80 x 3 O-ring; 55 x 3
Exchange of wear plates 1x 1x 2x 1x 2/4x 0/4/8/12x 2x
front wear plate rear wear plate radial casing liners O–ring 792 x 7 O–ring 54 x 4 O–ring 55 x 3 countersunk screw; M8 x 20
Exchange of fluid wetted parts 1x pump casing Pos. No.: 5 1x front wear plate Pos. No.: 10 1x rear wear plate Pos. No.: 11 2x radial casing liners Pos. No.: 12.1 4x clamping part Pos. No.: 12.2 2/4x socket head cap screw; M10 x 25 Pos. No.: 12.3 4x Sealing washer; A 10 x 16 Pos. No.: 12.4 2x stationary holding bush Pos. No.: 13 2x holding bush with thread Pos. No.: 14 2x mechanical seal Pos. No.: 15 2/4/6x distance bushing Pos. No.: 22 0/2x cover disc Pos. No.: 24 2x gasket Pos. No.: 25 1x O–ring 792 x 7 Pos. No.: 30 2/4x O–ring 54 x 4 Pos. No.: 31 2x O–ring 80 x 3 Pos. No.: 33 0/4/8/12x O–ring 55 x 3 Pos. No.: 34 2x countersunk screw; M8 x 20 Pos. No.: 52 2x hexagon head screw; M16 x 40 Pos. No.: 64 2x sealing washer; A 21 x 26 Pos. No.: 74 As special tools use the withdrawal tool (Pos. No. 90/91), the special tool for the holding bush (Pos. No. 95). Datei: BEDI-PL-1-08-01-E-0, Stand:25.10.01
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7.
Spare Parts regarding the Code Number
7.1
Code Number
The code number stamped to the pump nameplate identifies all fluid wetted parts the pump is furnished with. The code number is also recorded on the cover page of this operation and maintenance manual. To decode the pump code, refer to the attached code table.
7.2
Spare Parts List
The attached spare parts list is universal and contains all available combinations. Please use the pump code for identification.
Please order required spare parts at (please mention the article numbers):
BÖRGER GmbH Benningsweg 24 46325 Borken – Weseke Germany E – mail:
[email protected] Telefon: +49 (0)2862 / 9103 – 20 Telefax: +49 (0)2862 / 9103 - 46
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Standard-Assembly
Overhead mounted Drive Assembly
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Spare part list PL pumps
item
nomination
material
quantity
article-No.
100
200
300
400
1
gear case
EN-GJL-200
A20008
1
1
1
1
2
gear case cover
EN-GJL-200
A20108
1
1
1
1
3
bearing cap open
EN-GJL-200
A20208
1/2
1/2
1/2
1/2
4
bearing cap closed
EN-GJL-200
A20218
1/0
1/0
1/0
1/0
5
pump casing PL 100; FERROCAST
EN-GJL-250
B40118
1
-
-
-
pump casing PL 200; FERROCAST
EN-GJL-250
B40218
-
1
-
-
pump casing PL 300; FERROCAST
EN-GJL-250
B40318
-
-
1
-
pump casing PL 400; FERROCAST
EN-GJL-250
B40418
-
-
-
1
pump casing PL 200; nitrided hardening*
EN-GJL-250
B40228
-
1
-
-
pump casing PL 100; stainless steel
1.4517
B40138
1
-
-
-
pump casing PL 200; stainless steel
1.4517
B40238
-
1
-
-
pump casing PL 300; stainless steel
1.4517
B40338
-
-
1
-
pump casing PL 100; FERROCAST; MIP
EN-GJL-250
B40430
1
-
-
-
pump casing PL 200; FERROCAST; MIP
EN-GJL-250
B40440
-
1
-
-
pump casing PL 300; FERROCAST; MIP
EN-GJL-250
B40450
-
-
1
-
pump casing PL 400; FERROCAST; MIP
EN-GJL-250
B40460
-
-
-
1
pump casing PL 100; MIP; stainless steel
1.4571
B40130
1
-
-
-
pump casing PL 200; MIP; stainless steel
1.4571
B40230
-
1
-
-
pump casing PL 300; MIP; stainless steel
1.4571
B40330
-
-
1
-
8
pump casing cover
EN-GJS-400
B41008
1
1
1
1
9.1
rotor 2-lobe; PL 100
NBR
R82468
2
-
-
-
rotor 2-lobe; PL 100
EPDM
R82478
2
-
-
-
rotor 2-lobe; PL 100
FPM
R82458
2
-
-
-
rotor 2-lobe; PL 100
Haberflex
R82781
2
rotor 2-lobe; PL 200
NBR
R82568
-
2
-
-
rotor 2-lobe; PL 200
EPDM
R82578
-
2
-
-
rotor 2-lobe; PL 200
FPM
R82558
-
2
-
-
rotor 2-lobe; PL 200
Haberflex
R82791
-
2
-
-
rotor 2-lobe; PL 300
NBR
R82618
-
-
2
-
rotor 2-lobe; PL 300
EPDM
R82628
-
-
2
-
rotor 2-lobe; PL 300
FPM
R82608
-
-
2
-
rotor 2-lobe; PL 300
Haberflex
R82801
-
-
2
-
rotor 3-lobe
NBR
R82208
2
4
6
8
rotor 3-lobe
EPDM
R82308
2
4
6
8
rotor 3-lobe
FPM
R82408
2
4
6
8
rotor 3-lobe
PUR
R82508
2
4
6
8
rotor 3-lobe, auxiliary rotor
1.4571
R82908
-
2
4
6
rotor 3-lobe, front side
1.4571
R82908K
2
2
2
2
rotor 3-lobe, auxiliary rotor
PTFE
R82809
-
2
4
6
rotor 3-lobe, front side
PTFE
R82809K
2
2
2
2
rotor 2-lobe; readjustable; PL 100
NBR
R82668
2
-
-
-
rotor 2-lobe; readjustable; PL 100
EPDM
R82658
2
-
-
-
rotor 2-lobe; readjustable; PL 100
FPM
R82678
2
-
-
-
rotor 2-lobe; readjustable; PL 200
NBR
R82718
-
2
-
-
rotor 2-lobe; readjustable; PL 200
EPDM
R82708
-
2
-
-
rotor 2-lobe; readjustable; PL 200
FPM
R82728
-
2
-
-
rotor 2-lobe; readjustable; PL 300
NBR
R82758
-
-
2
-
rotor 2-lobe; readjustable; PL 300
EPDM
R82768
-
-
2
-
rotor 2-lobe; readjustable; PL 300
FPM
R82778
-
-
2
-
9.2
9.3
*
without MIP liners
ERSA-PL-1-6-01-E-1 Stand: 25.10.2001
Tabelle1
Spare part list PL pumps item nomination 9.4
10 11 12.1
12.2
12.3 12.4 13 14 15
material
quantity
article-No.
100
200
300
400
screw rotor; ccw; PL 100
NBR
R9323L9
1
-
-
-
screw rotor; cw; PL 100
NBR
R9323R9
1
-
-
-
screw rotor; ccw; PL 100
EPDM
R9324L9
1
-
-
-
screw rotor; cw; PL 100
EPDM
R9324R9
1
-
-
-
screw rotor; ccw; PL 100
FPM
R9325L9
1
-
-
-
screw rotor; cw, PL 100
FPM
R9325R9
1
-
-
-
screw rotor; ccw; PL 100
NR-SBR
R9326L9
1
-
-
-
screw rotor; cw, PL 100
NR-SBR
R9326R9
1
-
-
-
screw rotor; ccw; PL 200
NBR
R9327L9
-
1
-
-
screw rotor; cw, PL 200
NBR
R9327R9
-
1
-
-
screw rotor; ccw; PL 200
EPDM
R9328L9
-
1
-
-
screw rotor; cw, PL 200
EPDM
R9328R9
-
1
-
-
screw rotor; ccw; PL 200
FPM
R9329L9
-
1
-
-
screw rotor; cw, PL 200
FPM
R9329R9
-
1
-
-
screw rotor; ccw; PL 200
NR-SBR
R9330L9
-
1
-
-
screw rotor; cw, PL 200
NR-SBR
R9330R9
-
1
-
-
screw rotor; ccw; PL 300
NBR
R9331L9
-
-
1
-
screw rotor; cw, PL 300
NBR
R9331R9
-
-
1
-
screw rotor; ccw; PL 300
EPDM
R9332L9
-
-
1
-
screw rotor; cw, PL 300
EPDM
R9332R9
-
-
1
-
screw rotor; ccw; PL 300
FPM
R9333L9
-
-
1
-
screw rotor; cw, PL 300
FPM
R9333R9
-
-
1
-
screw rotor; ccw; PL 300
NR-SBR
R9334L9
-
-
1
-
screw rotor; cw, PL 300
NR-SBR
R9334R9
-
-
1
-
cover protection plate, NitroX
1.3401
B41018
1
1
1
1
cover protection plate, stainless steel
1.4571
B41028
1
1
1
1
axial casing protection plate, hardened steel
42CrMo4V
B41058
1
1
1
1
axial casing protection plate, stainless steel
1.4571
B51054
1
1
1
1
radial casing liners; PL100
XAR 400
B41060
2
-
-
-
radial casing liners; PL200
XAR 400
B41070
-
2
-
-
radial casing liners; PL300
XAR 400
B41080
-
-
2
-
radial casing liners; PL400
XAR 400
B41090
-
-
-
2
radial casing liners; PL100; stainless steel
1.4571
B41100
2
-
-
-
radial casing liners; PL200; stainless steel
1.4571
B41110
-
2
-
-
radial casing liners; PL300; stainless steel
1.4571
B41120
-
-
2
-
radial casing liners; PL400; stainless steel
1.4571
B41130
-
-
-
2
clamping part; PL100
1.0503
B41140
4
-
-
-
clamping part; PL200
1.0503
B41150
-
4
-
-
clamping part; PL300
1.0503
B41160
-
-
4
-
clamping part; PL400
1.0503
B41170
-
-
-
4
clamping part; PL100
1.4571
B41270
4
-
-
-
clamping part; PL200
1.4571
B41280
-
4
-
-
clamping part; PL300
1.4571
B41290
-
-
4
-
clamping part; PL400
1.4571
B41300
-
-
-
4
socket head cap srew; M10 x 25; 8.8
DIN 912
Z37810
4
8
8
8
socket head cap srew; M10 x 25; A4
DIN 912
Z37830
4
8
8
8
sealing washer; A 10 x 16
CU
Z31309
4
8
8
8
stationary holding bush, quality steel
42CrMo4V
D45218
2
2
2
2
stationary holding bush; stainless steel
1.4571
D45213
2
2
2
2
holding bush with thread; steel
42CrMo4V
D45114
2
2
2
2
holding bush with thread; stainless steel
1.4571
D45214
2
2
2
2
mechanical seal; cast iron; O - Ring; NBR
Hartg./NBR
D45008
2
2
2
2
mechanical seal; cast iron; O - Ring; EPDM
Hartg./EPDM
D45104
2
2
2
2
mechanical seal; cast iron; O - Ring; Viton
Hartg./FPM
D45204
2
2
2
2
ERSA-PL-1-6-01-E-1 Stand: 25.10.2001
Tabelle1
Spare part list PL pumps
item 15
nomination
material
quantity
article-No.
100
200
300
400
mechanical seal; cast iron; O - Ring; FEP
Hartg./FEP/FPM
D45307
2
2
2
2
mechanical seal; Sic/Sic; O - Ring; NBR
Sic/NBR
D45504
2
2
2
2
mechanical seal; Sic/Sic; O - Ring; EPDM
Sic/EPDM
D45604
2
2
2
2
mechanical seal; Sic/Sic; O - Ring; Viton
Sic/FPM
D45704
2
2
2
2
mechanical seal; Sic/Sic; O - Ring; FEP
Sic/FEP/FPM
D45807
2
2
2
2
O - Ring; 47,5 x 6,5
FEP/FPM
D55307
4
4
4
4
O - Ring; 47,5 x 6,5
NBR
D55317
4
4
4
4
O - Ring; 47,5 x 6,5
EPDM
D55327
4
4
4
4
O - Ring; 47,5 x 6,5
FPM
D55337
4
4
4
4
driving shaft; PL 100
42CrMo4V
W41114
1/2
-
-
-
driving shaft; PL 200
42CrMo4V
W41214
-
1/2
-
-
driving shaft; PL 300
42CrMo4V
W41314
-
-
1/2
-
driving shaft; PL 400
42CrMo4V
W41414
-
-
-
1/2
short shaft; PL 100
42CrMo4V
W41124
1/0
-
-
-
short shaft; PL 200
42CrMo4V
W41224
-
1/0
-
-
short shaft; PL 300
42CrMo4V
W41324
-
-
1/0
-
short shaft; PL 400
42CrMo4V
W41424
-
-
-
1/0
shaft with SAE - profile; PL 100
42CrMo4V
W41104
2
-
-
-
shaft with SAE - profile; PL 200
42CrMo4V
W41204
-
2
-
-
shaft with SAE - profile; PL 300
42CrMo4V
W41304
-
-
2
-
shaft with SAE - profile; PL 400
42CrMo4V
W41404
-
-
-
2
19.1
gear wheel with parallel keyway
42CrMo4V
E12104
1
1
1
1
19.2
gear wheel with parallel keyway
42CrMo4V
E12110
1
1
1
1
distance bushing, 3-lobe; rotor/rotor steel
42CrMo4V
C79904
-
2
4
6
distance bushing, 3-lobe; rotor/rotor st. steel
1.4571
C79919
-
2
4
6
16
17
18
22 24 25
30
31
33
cover disc for 3-lobe rotor; steel St 50
1.0050
C80004
2
2
2
2
cover disc for 3-lobe rotor; stainless steel
1.4571
C80104
2
2
2
2
gasket; PL 100
NBR
F82018
2
-
-
-
gasket; PL 100
EPDM
F82134
2
-
-
-
gasket; PL 100
FPM
F82144
2
-
-
-
gasket; PL 100
FEP/FPM
F82057
2
-
-
-
gasket; PL 200
NBR
F82028
-
2
-
-
gasket; PL 200
EPDM
F82234
-
2
-
-
gasket; PL 200
FPM
F82244
-
2
-
-
gasket; PL 200
FEP/FPM
F82067
-
2
-
-
gasket; PL 300
NBR
F82038
-
-
2
-
gasket; PL 300
EPDM
F82334
-
-
2
-
gasket; PL 300
FPM
F82344
-
-
2
-
gasket; PL 300
FEP/FPM
F82077
-
-
2
-
gasket; PL 400
NBR
F82048
-
-
-
2
gasket; PL 400
EPDM
F82434
-
-
-
2
gasket; PL 400
FPM
F82444
-
-
-
2
O - ring; cover; 792 x 7
NBR
O45408
1
1
1
1
O - ring; cover; 792 x 7
EPDM
O45424
1
1
1
1
O - ring; cover; 792 x 7
FPM
O45418
1
1
1
1
O - ring; cover; 792 x 7
FEP
O45438
1
1
1
1
O - ring; 54 x 4
NBR
O45508
2/4
2/4
2/4
2/4
O - ring; 54 x 4
EPDM
O45524
2/4
2/4
2/4
2/4
O - ring; 54 x 4
FPM
O45518
2/4
2/4
2/4
2/4
O - ring; 54 x 4
FEP
O45537
2/4
2/4
2/4
2/4
O - ring; 80 x 3
NBR
O45708
2
2
2
2
O - ring; 80 x 3
EPDM
O45724
2
2
2
2
O - ring; 80 x 3
FPM
O45718
2
2
2
2
O - ring; 80 x 3
FEP
O45737
2
2
2
2
ERSA-PL-1-6-01-E-1 Stand: 25.10.2001
Tabelle1
Spare part list PL pumps
item 34
nomination
material
quantity
article-No.
100
200
300
400
O - ring; distance bushing; 55 x 3
NBR
O45804
-
4
8
12
O - ring; distance bushing; 55 x 3
EPDM
O45824
-
4
8
12
O - ring; distance bushing; 55 x 3
FPM
O45814
-
4
8
12
O - ring; distance bushing; 55 x 3
FEP/FPM
O55807
-
4
8
12
36
oil seal; 45 x 70 x 10
NBR
S16508
1/2
1/2
1/2
1/2
37
double lip oil seal; 55 x 80 x 10 DUO
NBR
S16108
2
2
2
2
double lip oil seal; 55 x 80 x 10 DUO
FPM
S16118
2
2
2
2
40
cylinder roller bearing
DIN 5412
S14608
2
2
2
2
41
self-align roller bearing
DIN 635
S14508
2
2
2
2
42
hardened sleeve; 50 x 55 x 20
DIN 5405
S16008
2
2
2
2
43
hardened sleeve; 40 x 45 x 20
DIN 5405
S16708
1/2
1/2
1/2
1/2
46
parallel key; 14 x 9 x 32
DIN 6885
S14324
2
2
2
2
50
cover nut; M16
DIN 582
Z32208
4
4
4
4
52
countersunk srew; M8 x 20; stainless steel
DIN 7991
Z38208
2
2
2
2
53
screw stud M16 x 45
DIN 939
Z32108
4
4
4
4
dowel pin; 14 x 32
DIN 7979
Z33508
2
2
2
2
55.1 55.2
dowel pin; 14 x 40
DIN 7978
Z33608
2
2
2
2
56
hexagon head srew; M8 x 20
DIN 933
Z39108
12
16
20
24
57
hexagon head srew; M10 x 30
DIN 933
Z39208
12
12
12
12
58
hexagon head srew; M8 x 20
DIN 912
Z39308
12
12
12
12
59
hexagon head srew; M10 x 40
DIN 912
Z39408
12
12
12
12
60
lifting eye nut; M12
DIN 580
Z39508
1
1
1
1
61
spring washer; A10
DIN 127
Z39525
12
12
12
12
62
parallel key; driving shaft; A10 x 8 x 70
DIN 6885
Z39018
1/2
1/2
1/2
1/2
63
parallel key for 2-lobe rotors; 14 x 9 x 24
DIN 6885
S14338
2
-
-
-
parallel key for 2-lobe rotors; 14 x9 x 79
DIN 6885
S14348
-
2
-
-
parallel key for 2-lobe rotors; 14 x 9 x 70/64
DIN 6885
S14358
-
-
2
-
parallel key for 3-lobe rotors; 14 x 9 x 32
DIN 6885
Z39024
2
-
-
-
parallel key for 3-lobe rotors; 14 x 9 x 90
DIN 6885
Z39034
-
2
-
-
parallel key for 3-lobe rotors; 14 x 9 x 80/63
DIN 6885
Z39044
-
-
2
-
parallel key for 3-lobe rotors; 14 x 9 x 100/99
DIN 6885
Z39054
-
-
-
2
hexagon head srew; M16 x 40; (10.9)
DIN 6912
Z39608
2
2
2
2
hexagon head srew; M16 x 40 A4
stainless steel
Z39603
2
2
2
2
65
oil sight glass, brass; R1"
brass
Z18508
1
1
1
1
66
oil drain plug; R 1/2"
DIN 908
Z19308
2
2
2
2
67
breather; R 1/2"
brass
Z19108
1
1
1
1
69
stopper B 146
PE
Z19508
1
1
1
1
70
sealing washer; A 33 x 39
Klegerit/Cu
K22208
2
2
2
2
71
sealing washer; A 17 x 23
Cu
K32409
2
2
2
2
74
sealing washer; A 21x26
Cu
K22408
3
3
3
3
77
Circlip J 110
DIN 472
K23008
2
2
2
2
78
gear case locking srew; R1"
DIN 910
Z22815
1
1
1
1
80
sealing compound (tube 50 ml)
U22308
1
1
1
1
sealing compound (tube 250 ml)
U22208
1
1
1
1
64
90
withdrawl tool for 3-lobe rotor body
S235JR
U22908
1
1
1
1
91
withdrawl tool for 2-lobe rotor body
S235JR
U22918
1
1
1
1
93
special tool for mechanical seal
U22948
1
1
1
1
95
special tool for holding bush
U22968
1
1
1
1
ERSA-PL-1-6-01-E-1 Stand: 25.10.2001
E295
Tabelle1
CODE-ALLG-1-06-01-E, Rev.: 1
CODE-LIST no. part
material/design
remark
1
pump type
2
pump casing
EN - GJL - 250 EN - GJL - 250 EN - GJL - 600 -3 stainless steel 1.4517 stainless steel 1.4517 EN - GJL - 250 MIP XAR 400 EN - GJL - 250 MIP 1.4571 EN - GJL - 250 MIP 1.4571 Edelstahl 1.4517 special design
3
rotor design
2 - lobe (AL / PL / FL) 3 - lobe (AL / PL) 2 - lobe readjustable (PL) 3 - lobe screw rotor (PL) 3 - lobe linear rotor tip (FL) 3 - lobe linear rotor tip, rotor body in stainless steel (FL) 3 - lobe with screw rotor tip (FL) 3 - lobe with screw rotor tip, rotor body in stainless steel (CL/FL)
4
rotor material
NR-SBR NBR EPDM FPM PUR stainless steel, 1.4571 PTFE Hypalon, CSM
5
O-rings
NBR EPDM FPM PTFE
6
material of lip seal
NBR Viton special design
7
8
9
10
flange gasket
mechanical seal
shaft design and positioning
codenumber
AL 25 AL 50 AL 75 PL 100 PL 200 PL 300 PL 400 FL 518 FL 776 FL 1036 FLA 518 FLA 776 FLA 1036 FLA 1540 FLA 2072 FLA 3080 CL260 CL390 CL520
NBR EPDM FPM PTFE special design mechanical seal, cast iron mechanical seal, cast iron mechanical seal, cast iron mechanical seal, cast iron mechanical seal, Sic/Sic mechanical seal, Sic/Sic mechanical seal, Sic/Sic mechanical seal, Sic/Sic gland packing gland packing with flushing port MULTI-SEAL K MULTI-SEAL L special design
standard standard nitrided hardened laser hardened standard plasma hardened MIP standard MIP with stainless steel casing liners MIP with complete stainless steel linig MIP with stainless steel casing liners design in compliance with the order
design in compliance with the order
design in compliance with the order O - ring: NBR O - ring: EPDM O - ring: FPM O - ring: PTFE O - ring: NBR O - ring: EPDM O - ring: FPM O - ring: PTFE
three PTFE shaft sealing rings seven PTFE/NBR shaft sealing rings design in compliance with the order
1x cylinder top drive shaft 1x cylinder bottom drive shaft 2x cylinder drive shaft 2x drive shaft, SAE - profile 1 3/8" 1x top drive shaft, SAE - profile 1 3/8" 1x bottom drive shaft, SAE - profile 1 3/8" 2 x drive shaft, SAE - profile 1 3/4" (FL1036) 1 x top drive shaft, SAE - profile 1 3/4" (FL1036) 1 x bottom drive shaft, SAE - profile 1 3/4" (FL1036)
manual edition no.
codenumber 11
optional special design by requirement in addition to the codenumber
created Abel: 21.06.2001 Stand: 30.07.2002
A B C D E F G H I K S T U M O R Q V W : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
A B C D E F G H I X : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
A B C D E F G H : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
A C D I P E T H : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
C D I T : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
C I X : : : : : : : : : : : : : : : : : : : : : : : : : : : : : : :
C D I T X : : : : : : : : : : : : : : : : : : : : : : : : :
A B C D E F G H I J K L X : : : : : : : : : : :
A B C D E F G H I :
:
:
:
:
:
:
:
:
:
4
4
horizontal, rotated set up vertical set up sealsensor temperature control
pump 90° rotated pump will be mounted hanging leak sensor in the intermidiate chamber temperature sensor in the pump casing
L H D Z
special design
design in compliance with the order
X
Datei: CODE-ALLG-1-06-01-E-1
Betriebs- und Wartungsanleitung Operating and Maintenance Instruction Instructions de conduite et d’entretien Diese Sicherheitshinweise sind aufzubewahren These safety instructions must be kept available Ces instructions de sécurité doivent être observées
Block – Stirnradgetriebe Unicase Helical Gearboxes Monobloc Réducteurs à engrenages cylindriques
B 1010 09/2000
D
GB
F
∆ Warnung
Es wird vorausgesetzt, daß die grundsätzlichen Planungsarbeiten der Anlage sowie Transport, Montage, Installation, Inbetriebnahme, Wartung und Reparaturen von qualifiziertem Personal ausgeführt bzw. durch verantwortliche Fachkräfte kontrolliert werden. Bei Arbeiten am Getriebemotor muß garantiert sein, daß keinerlei Spannung anliegt, und dieser gegen Wiedereinschaltung gesichert ist. ∆ Warnung
Veränderungen gegenüber dem Normalbetrieb (höhere Leistungsaufnahme, Temperaturen, Schwingungen, Geräusche usw. oder Ansprechen der Überwachungseinrichtungen) lassen vermuten, daß die Funktion beeinträchtigt ist. Zur Vermeidung von Störungen, die ihrerseits mittelbar oder unmittelbar schwere Personenoder Sachschäden bewirken könnten, muß das zuständige Wartungspersonal dann umgehend verständigt werden.
∆ Caution
It is presumed that fundamental project work as well as all work with regard to transport, assembly, installation, starting-up, maintenance and repair is performed by qualified personnel or supervised by skilled labour taking overall responsibility. Make absolutely sure that no voltage is applied at all while work is being done on the geared motor. Drive must also be secured against switching on. ∆ Caution Any deviation from normal operating conditions (increased power consumption, temperature, vibrations, noise etc.) or warning signals by monitoring equipment suggest malfunction. Inform the responsible maintenance personnel at once to prevent the trouble from getting worse and causing, directly or indirectly, serious physical injury or material damage.
∆ Avertissement
Il est impératif que les travaux fondamentaux de l'installation, ainsi que tous les travaux de transport, montage, installation, mise en exploitation, entretien et réparation soient accomplis par du personnel qualifié et contrólés par des techniciens spécialisés dans ce domaine. Avant toute intervention sur le motoréducteur, il faut s'assurer que celui-ci n'est plus sous tension et que la remise sous tension soit interdite. ∆ Avertissement
Si en utilisation normale, des modifications de fonctionnement apparaissent telles que puissance absorbée trop élevée, température élevée, vibrations fortes, bruit intense etc. ou en rapport avec les contrôles techniques, cela laisse supposer que différentes fonctions de l'appareil peuvent être détériorées. Pour éviter ensuite des problèmes, qui pourraient entraîner de graves accidents corporels ou de graves dégats matériels, le personnel d'entretien compétent doit immédiatement être informé.
∆ Im
Zweifelsfall die entspechenden Betriebsmittel sofort abschalten!
∆ In
case of doubt disconnect the m achine immediately!
∆
Si vous êtes dans le doute, coupez immédiatement l'alimentation!
Aufstellung, Vorbereitung − Transportösen am Getriebe sind für das Gewicht des Antriebs ausgelegt − Fundamente ausreichend bemessen und schwingungsfrei ausführen − Getriebe oder -motor fest und ohne Verspannung montieren − ausreichende Belüftung vorsehen − serienmäßiges Innengewinde nach DIN 332 zum Aufziehen von Verbindungselementen auf die Wellen benutzen auf die Wellen vermeiden − Schläge (Lagerbeschädigung!) und Getriebe möglichst mit − Maschine elastischen Kupplungen verbinden dem Einschalten Abtriebselemente − vor aufziehen bzw. Paßfeder sichern Drehmoment− bei Aufsteckgetrieben mit stütze Gummipuffer verwenden
Preparing and performing installation − Lifting devices on the drive are designed to carry the drive weight − the foundation (base) should be of adequate size and vibration-proof − install gear unit or geared motor rigid and braceless − ensure sufficient ventilation − make use of tapped hole (DIN 332) to suit fastening to the shaft end − avoid shocks on shafts (bearing damage! ) − preferably use flexible coupling between output shaft and driven machine − fit output elements to shaft end or secure feather key before starting the motor − use torque arm with rubber buffer on shaft mounting gearboxes
Mise en place, préparation − Le matériel utilisé pour la manutention doit tenir compte du poids de l'équipement − prendre largement les dimensions des embases et les réaliser exemptes de vibrations − monter les réducteurs et motoréducteurs solidement et sans haubanage − prévoir une aération suffisante − prévoir le taraudage conforme à la norme DIN 332 pour monter des accouplements sur les arbres d'entrée et de sortie − éviter de donner des coups sur les arbres (cela pourrait détériorer le roulement!) − lier autant que possible la machine et le réducteur avec des accouplements élastiques − avant la mise en service, enlever l'élément d'accouplement ou/et fixer la clavette − utiliser pour l'exécution arbre creux avec bras de réaction une butée en caoutchouc
Elektrischer Anschluß − Motoranschluß nach Schaltbild vornehmen − Übereinstimmung von Netzspannung und Frequenz mit den Typenschild-Daten sicherstellen − Sichere Schutzleiterverbindung herstellen − evtl. falsche Drehrichtung korrigieren durch Vertauschen von 2 Phasen − Nicht benötigte Kabeleinführungsöffnungen und den Kasten selbst staub- und wasserdicht verschließen − Überbelastung und Phasenausfall durch Schutzschalter vorbeugen − Einstellen des Motorschutzschalters auf Nennstrom − Schaltbilder auf der letzten Seite
Connection of motor − Connect motor according to diagram − make sure that mains voltage/frequency are in accordance with nameplate information − make secure protective conductor conection − if motor is running in reverse direction, interchange two phases − Close unused cable entrances holes and the box itself in a dust- and watertight manner. protective switches to prevent − install overload and phase failure − set motor protection switch to nominal current − wiring diagrams on the last page
Branchements électriques − brancher le moteur selon le schéma − s'assurer que la tension du réseau et la fréquence correspondent aux données inscrites sur la plaque signalétique − Le cable de raccordement doit être protégé − corriger un éventuel mauvais sens de rotation par une inversion de deux phases − Les entrées de câbles non utilisées doivent être obturées, la boîte elle-même devant être fermée de façon à être étanche à l'eau et à la poussiére − prévoir une protection électrique contre les surcharges, court-circuit et défaut de phases la protection électrique suivant − régler l'intensité nominale du moteur − schéma de branchement à la derniére page
Inbetriebnahme − bei längeren Lagerzeiten besondere Vorkehrungen treffen (siehe Werknormblatt "Langzeitlagerung") − Lage der Ölstandschraube nach Bauformtabellen des entsprechenden Kataloges feststellen − Prüfen des Ölstandes des Verschlußstopfens vor − Entfernen Inbetriebnahme (Überdruck!), ggf. Druckentlüftungsschraube montieren Erstbefüllung: siehe Schmier− Normale stofftabelle − Luftgekühlte Motoren sind für Umgebungstemperaturen von - 20°C bis +40°C sowie Aufstellungshöhen â 1.000 m über NN ausgelegt − Der Einsatz im Ex-Bereich ist nicht zulässig, sofern nicht ausdrücklich hierfür vorgesehen
Starting up − in case of long-time storage take special precautions (as provided in works standard sheet "Extended Storage") − check position of oil-level plug with help of mounting position tables in applicable catalogue − check oil-level − prior to starting-up, remove vent plug from vent screw if necessary − if not specified otherwise, first oil filling as is shown in list of lubricants − air-cooled motors are designed for ambient temperautres between -20°C and +40°C and for installation at altitudes â 1.000 m above M.S.L. − Their use in hazardous areas is prohibited unless they are expressly intended for such use (follow additional instructions)
Mise en fonctionnement − si un stockage longue durée du réducteur est prévu, il faut prendre les dispositions nécessaires (voir spécification "Stockage longue durée") − vérifier que la vis de niveau d'huile corresponde à la position de montage du réducteur (voir catalogue) − contrôler le niveau d'huile − enlever la mèche de la vis d'évent avant la mise en route (pour éviter une surpression) ou fixer le clapet d'évent sur le réducteur − pour le premier remplissage voir le tableau des lubrifiants − les moteurs autoventilés sont dimensionnés pour des températures ambiantes comprises entre -20°C et +40°C, ainsi que pour une altitude â 1000 mètres au-dessus du niveau de la mer − Leur utilisation dans des atmosphères explosives est interdite, à moins qu'elles ne soient expressément prévues à cet effet (respecter les indications supplémentaires)
Wartung MOTOR − Staubablagerungen entfernen (Überhitzung!) − Wälzlager ausbauen, reinigen und einfetten − Es ist zu beachten, daß der gesamte Freiraum um das Lager ca. 1/3 mit Fett gefüllt ist − Schmierstoffsorten siehe unten
Maintenance MOTOR − remove dust deposit (overheating) − dismount anti-friction bearings for cleaning and refill with grease − ensure that the bearing cage is packed to about 1/3 with grease, distribute evenly − select proper type of lubricating grease from following table
GETRIEBE − regelmäßige Ölstandskontrolle − Wechseln des Schmierstoffes alle 10.000 Betriebsstunden oder spätestens nach 2 Jahren. − Doppelte Fristen bei synthetischen Pro-dukten − Verkürzung der Schmierstoffwechselinter-valle bei extremen Betriebsbedingungen (hohe Luftfeuchtigkeit, aggressive Um-gebung und hohe Temperaturschwankungen) des Schmierstoffwechsels mit − Verbinden gründlicher Reinigung des Getriebes
GEARBOX − regular oil level check − change lubricant every 10.000 working hours or after two years at the latest. − combine the lubricant change with thorough cleaning of gear unit − lubricant changing intervals will be twice as long if synthetic products are used − extreme working conditions (high air humidity, aggressive media and large temperature variations) call for reduced lubricant changing intervals
∆ Synthetische
∆
und mineralische Schmierstoffe nicht miteinander mischen! Das gilt auch für die Entsorgung der Schmierstoffe!
DU REDUCTEUR − vérifier régulièrement le niveau d'huile − vidanger le lubrifiant après 10.000 heures de fonctionnement ou au plus tard après 2 ans d'utilisation. − profiter de la vidange pour effectuer un nettoyage approfondi du réducteur − pour des lubrifiants synthétiques, ce délai peut être doublé − réduire les intervalles entre les vidanges dans des conditions d'utilisation extrêmes (hygrométrie élevée, ambiance agressive ou variations importantes des températures)
Synthetic and mineral lubricants must not be mixed either for filling or for disposal!
ÖLFÜLLMENGE [cm3]
Stirnradgetriebe einstufig
Entretien DU MOTEUR la poussière du moteur − enlever (échauffement) − démonter les roulements, les nettoyer et les regraisser − la cage des roulements doit être remplie au 1/3 environ − lubrifiant voir tableau ci-après
CAPACITY [cm3]
∆ Des
lubrifiants synthétiques et minéraux ne doivent pas étre mélangés! Ceci s'applique également pour le retraitement des lubrifiants!
QUANTITE DE LUBRIFIANT [cm 3]
Waagerechte Anordnung Horizontal position Position horizontale Helical Gearboxes single reduction
Senkrechte Anordnung Vertical position Position verticale Réducteurs à engrenages cylindriques à un train d’engrenages
SK 11 E SK 21 E SK 31 E SK 41 E SK 51 E
B3 B6 250 350 600 1.000 1.100 1.700 1.700 2.600 2.200 3.400 Stirnradgetriebe zweistufig
B7 350 1.000 1.700 2.600 3.400
B8 550 1.200 2.200 3.300 4.700
B5 B 5I 300 500 500 1.100 800 1.650 1.000 2.800 1.800 4.100 Helical Gearboxes double reduction
B 5II 400 900 2.000 3.300 3.800
SK 02 SK 12 SK 22 SK 32 SK 42 SK 52 SK 62 SK 72 SK 82 SK 92 SK 102
B3 B6 150 400 250 500 500 1.350 900 2.000 1.300 3.200 2.500 5.100 6.500 15.000 9.000 23.000 14.000 32.000 25.000 52.000 36.000 71.000 Stirnradgetriebe dreistufig
B7 400 500 1.350 2.000 3.200 5.100 15.000 23.000 32.000 52.000 71.000
B8 700 850 2.000 3.000 4.500 6.800 13.000 18.000 27.000 47.000 66.000
B5 B 5I 250 600 350 900 700 2.000 1.300 3.300 1.800 4.500 3.000 6.200 7.000 14.000 10.000 18.500 15.000 29.000 26.000 47.000 40.000 66.000 Helical Gearboxes triple reduction
B 5II 500 600 1.550 2.400 3.700 5.600 16.000 23.000 34.500 52.000 72.000
B 5III 1 3 5 6 400 300 350 400 500 900 700 1.400 1.000 1.200 2.000 1.100 1.300 2.300 2.700 3.300 1.600 2.600 2.500 2.600 3.800 3.000 3.500 4.000 4.400 Réducteurs à engrenages cylindriques à deux trains d’engrenages B 5III
1 3 5 6 600 600 600 600 900 850 750 750 1.800 2.000 1.800 1.800 3.100 2.900 2.900 2.500 4.000 4.400 4.300 5.800 7.400 6.800 6.800 7.000 18.500 15.000 16.000 15.000 28.000 23.000 26.000 23.000 45.000 37.000 44.000 35.000 78.000 73.000 76.000 73.000 104.000 81.000 102.00 79.000 Réducteurs à engrenages cylindriques à trois trains d’engrenages
B3 B6 B7 B8 B5 B 5I B 5II B 5III 1 3 300 600 600 800 500 900 800 800 1.100 800 SK 03 600 700 700 1.100 850 1.200 950 950 1.200 1.200 SK 13 1.300 1.600 1.600 2.300 2.500 1.500 2.800 2.800 2.800 2.600 SK 23 1.600 2.300 2.300 3.200 1.900 3.500 2.600 2.600 4.400 3.400 SK 33 N 3.000 3.600 3.600 5.200 3.500 5.000 4.100 4.100 6.100 5.700 SK 43 4.500 6.000 6.000 7.700 5.200 7.000 6.700 6.700 8.900 8.400 SK 53 10.000 13.000 13.000 11.000 11.000 12.000 14.000 14.000 18.000 14.000 SK 63 14.000 20.000 20.000 17.500 14.000 18.000 20.000 20.000 27.500 22.500 SK 73 22.000 33.000 33.000 26.000 23.000 27.000 34.000 34.000 40.000 34.000 SK 83 40.000 49.000 49.000 44.000 40.000 44.000 49.000 49.000 74.000 70.000 SK 93 55.000 67.000 67.000 55.000 55.000 59.000 67.000 67.000 99.000 78.000 SK 103 Die Normalbefüllung der Getriebe ist Mineralöl. Synthetisches Öl ist gegen Mehrpreis lieferbar. Standard lubricant for the gearboxes is mineral-oil. Synthetic oil is available at a surcharge. Les réducteurs sont remplis d’huile minérale. Ils peuvent être remplis d’huile synthétique contre supplément de prix. HINWEIS / REMARK / REMARQUE: Ölfüllmengen sind ca.Angaben. Ölniveau anhand der Ölkontrollschraube prüfen. Filling quantities are approx. figures. Oil level must be checked according to oil-level plugs. Les quantités d`huile sont données à titre indicatif. Vérifier la quantité d’huile grâce à la vis de niveau d’huile.
5 900 1.200 2.350 4.200 6.600 8.700 16.000 27.000 37.000 72.000 97.000
6 1.000 1.250 2.400 2.900 5.600 8.700 14.500 20.000 31.000 70.000 71.000
2 0 2 l 2 / o 0 b 2 i r 0 T 4
x u a e l u o r à s t n e m e l u o r r u o p t n a i f i r b i l e d e p y T / s g n i r a e b n o i t c i r f i t n a r o f t n a c i r b u l f o e p y T / r e g a l z l ä W r ü f n e t r a f f o t . s r p e e m . t i e p n t a m m i h s g t e b c n m u t S b n a . e e i g b p m m m e U A T
l l o 5 o 9 b 9 b 8 i i r 7 r 4 T 3 T 3
a i 2 n a R l v a i A l l n l a l 2 e v e h l h L S A S R
l l 7 e h e r e S s d o r a e o e r 6 A G 1
e e p m m m i i t t e t g 2 g 1 i 2 n D n D t p G o o L P L P O L
y 8 o 8 4 l l 9 A b p o u T l o o i M B
y f o o l l o r M A F - P - 2 b d u l o 3 o o 2 M F 8
a i 2 l l n B e a v h l L S A R
a d i s s a C l l 2 e S h L S R
4 8 5 F E
n e 2 e b F O U
t t e B f r e 0 i 0 m 1 h E c S U
2 - e l s 0 i a b 1 o e r M M g F
-
p m e 2 t l 3 i b C o H M S
2 x 3 e l 1 p r 1 e 4 b M ü l E K B
-
s a N p o o T 2 o 3 2 3 i r 8 1 b x 5 m e 2 e l a Y b 7 f A t ü o e H l s C I N P G K M
h 1 t n 5 y 1 s r 4 e 1 b 1 ü l H K U
0 6 1 A W F t i l o n e R
9 1 6 1 P J t i l o n e R
2 2 T L S H t t i l i l o o n n e e R R
S 2 l e g o t n a l P
1 t i l G o F n 7 e R G
2 x u l i b o M
t t 2 e n f o r k c h c e e w a e M z B -
n o c a 5 e 2 B 3
-
m u r 0 a 3 C 3
0 2 o d n a s s i l G
P E B r o c F s L i D 2
2 P E E n o l o D
1 A R F x i m a T
P A l P l o o t r E r c 6 e V e u / 4 e Z e 2 d L h L h p p P o r 3 8 S 2 S E P 7
c e t o i B
T H 2 e b e u s l a a r t i e V G
e s a e r g r 2 e n S E L
2 P - E o e i B s a P e r B g
e s a e r g r 2 e P n M B E F
2 P b E u B l a r A A B
2 P E e l s a r a e u r E G
C ° 0 4 . . . 5 2 -
C ° 0 4 . . . 5 2 -
-
-
-
b b 2 b 2 u 2 l u L l u L l a r L a r E a r K A H A S A S
C ° 0 ) 6 l . a . . m 0 r 3 o n - (
C ° 0 4 . . . 0 5 *
C ° 0 8 . . . 5 2 *
- ) t t e ) l t r s s r t s a e 1 e e a r e ) i a e n ) f s t e l v t F l s e l e e l f r s e b b t a i n a a r e s a e F e u e 1 o h r t a b g t e o m c b u h e d r s t l m d i s d i ( é p e ö ) s i c i ( r f t c r a n q a ) l i a a n m n n i e a e r s t t r s b g e e r s h g 1 e n t e o a d a a e i e e e e t i i r s s s m i g n c - e s é s s n g u s o c f e s h h i e s e t t t i s t s é e l d a i s i i a i r e m e i h l o a d a i r e r t t i n a l d b h p b n t n g o p e r a i y y r a n i b o r e r a o b a v m c y u y b e M r l o e i u e i e ä r r n i l y o b i r F u F ( G o G h S F S G s B a B G G b L t g G e a S T l T l
x n u a e i z c t é e p s d s u e z s t é n u i i e e é t b h c ä t n i t l a t a s u é u m ’ q d f f t y t s o i t s l i a n k o r u q j e l s e a d W i r r e r e r t e s e a i l d m i n l t u o i a ’ s c d e u b e p i e n s l i a e f a y g o l n s i i r t g , C h i c n r ° i d g 0 6 n i n n e l l l o r e a e i v s W n f e d t a n h à i s s e r C u ° C e i 0 ° 0 r 6 6 é . b l x p a o u s h r r u e p o b p a o e C d v ° n o 0 u b 3 a à C ° d e 0 n r 3 - a u e i b C r l ° é a 0 f h n i r 3 e - e t w t n l n u o a e i n b b e r s m u e t r a a u e r t r e a u t p r a r m e p é e m t s t e p m g t e n n t u e e b i e b n g m u ’ m a d U h s r i t o e i L B W * * *
0 7 5 3 . 8 7 1 A D F / 1 H 0 7 n 5 i o 3 . t p 8 i 7 r 1 c s A 0 e D 7 r p F 5 t / 3 . n 1 8 a 7 v H 1 i t u f i r A s h D s c F e s s r l s i o a v V o a r g h r c p + p a a e n i r e 1 t t H t - a e n e F A m i + D S l a e U t l Ö h t n e e i h w m c t s e i l n g n a n ä o r c r t r i r i e b v v l u n l e e t e r t d u i o m a r s g p n s e e d l b o i e o u L F H ) ) ) 1 1 1
BAUFORMEN MOUNTING POSITIONS POSITIONS DE MONTAGE Waagerechte Anordnung Horizontal position Position horizontale SK 11 E - SK 51 E
SK 02 - SK 52
SK 62 - SK 103
SK 03 - SK 53 SK 63 - SK 103
B3 SK 62 - SK 102 SK 62 - SK 102
B6 SK 63 - SK 103
B7
B8
SK 63 - SK 103
B5
SK 62 - SK 102
B5I
SK 62 - SK 102
B 5 II SK 63 - SK 103
B 5 III
Senkrechte Anordnung Vertical position Position verticale
SK 11 E - SK 51 E
SK 02 SK 52
SK 03 SK 53
SK 62 - SK 103
SK 63
V1 *
V3
SK 63
V5 *
V6
Symbole: Symboles: Symboles:
Entlüftung Vent plug Event
Ölstand Oil level Niveau d’huile
Ölablaß Drain plug Vidange
Befestigung Mounting surface Fixation
Schaltbilder / Wiring diagrams / Schémas de branchement Drehstrom-Motor mit Kurzschlußanker Three phase squirrel-cage motor Moteur triphasé à cage d’écureull I) Klemmbrett Terminal board Plaque à bornes II) Schalter Switch Démarreur
Drehstrom-Motor mit Kurzschlußanker, in DahlanderSchaltung Three phase squirrel-cage motor, Dahlander connection Moteur triphasé à cage d’écrureull, couplage Dahlander
niedrige low inférieure
- Drehzahl - speed - vitesse
- hohe - high - supérieure
Drehstrom-Motor, polumschaltbar, zwei getrennte Wicklungen Three phase motor, polechanging, two separate windings, tw o speeds Moteur triphasé à commutation de pôles, deux bobinages séparés, deux vitesses
niedrige low inférieure
- Drehzahl - speed - vitesse
- hohe - high - supérieure
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item E1
Service Type: Description
Emer enc fire um SFN 80 Centrifugal pump with axial inlet
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61365
32 1030 72,00 -0,50 8,50 9,00 29,00 33,40 3555 4,90
Materials
Pump
Bearings Coupling Shaft seal
Casing : Bronze G-CuSn10 Impeller : NiAl-Bronze Wear rings : Bronze G-CuSn12 Shaft : Stainless steel Type : Rolling contact Lubrication : grease Type : flexible Type : Packing Material : Ramie + PTFE
Connections
suction side : pressure side
DN 80 80
PN 16 16
Type
: priming unit ASED 220V priming unit with liquid ring pump, seawater resistant mounted on pump
Type Execution Starting (V / Hz) (kW) (A) (A)
: : : : : : :
Pump / e-motor
(kg)
:
Classification
GL, certificate for pump Pump : 29736 BH, T.P. 15 bar 02 GL 05
Self-priming unit Prime mover
E-Motor
Power supply Power Rated current Starting current
WEG CSM 200 L-2 IM V1, IP 55, ISO B Transformer 440 / 60 34,00 54,20 406,00
E-Motor Nr.
: BP 09777
PTC : SPM : no Space heater : yes
Weights
107,00
/
239,00
Total
(kg)
: 346,00
16.02.2005
Operating instructions for centrifugal pumps 1.0 General Directions Every pump is subjected to a trial run on our test field and delivered in a fully operational shape . The present Operating Instructions are intended to inform the operators an expert exploitation . No liability would be assumed for damages resulting from the inobservation of these instructions . A guarantee within the framework of our terms of delivery would be granted only if the pump is being used for the service conditions identified and confirmed ( rating plate ) In all queries and spare parts orders , please state the following details: ( See rating plate ) 1. Works No. 2. Pump Type / Size 3. Year of Manufacture 4. Designation of the replacement parts needed , by specifying the sectional drawing number and parts items . Should the pumping set not immediately be taken into operation , then check the pump interior for humidity and dry it out . A means of preservation should be applied in case of a prolonged storing period .
2.0 Installation of Pump The resident superintendents has to advise the erection personnel of the safety requirements and of particular local regulations . Connection of the pump to the piping system has to be established free of any stresses , which means that all forces and moments resulting from the system are to be intercepted before junction points . Where the pump is delivered without drive motor , the electric motor has to be carefully sighted via the coupling and the alignment be checked according to appendix A. If non steel pipes are employed for the sea-water pump line, such as inside coated or CuNiFe pipes, the sacrifice pipe or the anode (Zn or Fe) must be always installed near the pump suction. After installation of the pump aggregate, the alignment of the flexible coupling must be checked according to appendix A. Final Check: The pumping set must allow for an easy manual rotation on the coupling . Verification of the Sense of Rotation: The sense of rotation must coincide with the rotation sense arrow shown on the pump . Verify the sense of rotation by shortly starting the drive of the liquid filled pump.
3.0 Commissioning / Stopping 3.1 Preparation: Fill the volute casing of the pump with the medium to be conveyed . Open the suction sided shut-off fitting for full passage . 3.2 Starting: Start up the pump against the closed pressure gate valve . As soon as the pump commences delivery with its full discharge power ( p ressure increase on delivery sided pressure gauge ) , slowly open the shut-off fitting . ( An extended run of the pump against t he closed shut-off fitting is not permitted . Inadmissible heating ) The pump must be protected against back flow (non-return flaps on the suction and delivery side) and pressure shocks. 3.3 Stopping: Close the pressure gate valve . In the presence of non-return fittings ( pressure sided ) , the pump may be stopped without taking any further measures .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 1 of 8
3.4 Shutdown: If the pump is not used for prolonged periods , clean and preserve all components . Store the pumping set in a dry state . For the stand-by-pumps care is to be taken , that the pump shaft will be turned appr. twice a week to avoid damages of the bearings by vibration .
4.0 Operational Supervision 4.1 Operating Point: Continuously supervise the operational discharge head of the pump ( for data refer to rating p late ) as the difference of the pressure readings between pressure and suction flanges of the pump .Correct it by a regulating fitting to be provided on the discharge side . 4.2 Bearings: Pump Type VNF : Attention! Leakage holes at bearing seat must be always open in case mechanical seal is leaking - so that no water can run into the bearings ! Regularly check the running noise of the b earings . A uniform , purring sound is audible in the event of an unobjectionable bearing contact . Damaged bearings cause a loud , irregular , chattering noise . (In such a case, examine the bearings.) 4.3 Shaft Seals: Shaft seals must never run dry , not even for short periods ! 4.3.1Mechanical Gland Seals: In operation , mechanical gland seals are running free of leakages , which means that the low quantity of conveying medium required for lubrication evaporates when escaping from the sealing gap . Supervise the escape of leaking water in the range of the seal or at the checking outlet . If a drop bydrop escape of fluid is exceeded , then examine the mechanical gland seal . Replace it , if necessary . 4.3.2Stuffing Boxes: When using packing material ( stuffing box ) , allow for a generous leakage during the running-in period ( about 2 hours ) of the packing rings . During the further operation , uniformly read-just the stuffing box gland until the leakage decreases to the desired minimum ( slight dripping ) . During this procedure , check shaft and stuffing box for temperature rise. In the event of symptoms for overheating , do not tighten the gland any further but slacken it slightly so as to again achieve the normal temperature by an increased leakage . Afterwards , slightly readjust the gland until the escape of leakage is again under control . If both temperature and tightness have themselves adjusted to a uniform value , a check is still required at prolonged time intervals . 4.4 Suction Sided Fittings: All fittings ( filters , butterfly valves , gate valves etc. ) are to be continuously examined for full passage .
5.0 Maintenance 5.1 Bearings (Pump) All pumps are delivered with grease lubricated rolling contact bearings . Regrease through a grease nipple by using a grease gun . The regreasing intervals and the quantities of grease to be refilled are obvious from the table given below .
During all disassemblies - but not exceeding 4 years - carefully clean the bearings from old grease residues . then reintroduce the new charge by spreading or refilling bearing grease into all bearing cavities between the rolling elements . As a lubricant , use quality rolling contact bearing greases having the following specification : Saponification basis: Dripping point: Handling temperatures: Walk penetration: Standard:
LITHIUM with anti-corrosion additives , water repellent about 190°C . -30°C up to +120°C . 250 to 295 SEB 181252 SEB 18103 K3K
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 2 of 8
5.0
Maintenance
List 1 for: VNF1/290, 1/325, 2/300, 2/325, 2/400, 3/300, 3/325, 3/400, 4/300, 4/325, 5/300, 5/325 and for all sizes of the pumptypes SFN, SFS, STN, STS
DN D
Regreasing Interval (hours)
Regreasing Quantity gram/bearing
(discharge side DN)
rpm 1450
rpm 1750
rpm 2900
rpm 3500
Up to DN 100
13.000
11.000
8.000
7.000
8
DN 125-150
12.000
10.000
7.500
6.200
10
DN 200-250
11.000
9.500
6.500
4.800
15
DN 300-350
10.000
9.000
20
List 2 for: all sizes of pumptypes VRW + VRF and for VNF5/420, 7/300, 7/350, 7/420, 8/300, 9/325
DN D (discharge side DN)
Regreasing Interval (hours)
Regreasing Quantity gram/baring
rpm
rpm
rpm
rpm
1450
1750
2900
3500
Up to DN 100
3.000
2.000
1.000
800
15
DN 125-150
2.500
1.700
900
700
15
DN 200-250
2.000
1.500
700
480
20
DN 300-400
1.700
1.200
25
List 3 for VRF 11/420D G
DN D (discharge side DN)
DN 400 – 500
Regreasing Interval (hours) rpm 950
rpm
rpm
rpm
1150
1450
1750
2.200
1.900
1.300
1.000
Regreasing Quantity gram/baring
25
5.2 Mechanical Gland Seal Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 3 of 8
Mechanical gland seals do not necessitate any particular maintenance during operation . 5.3 Stuffing Boxes Stuffing box packings must not seal definitely tight . A dripping leakage is necessary to prevent overheating or even burning of the packing due to frictional heat . Retighten the packing in compliance with item 4.3 in the event of heavy leakage . Commence with replacing individual packing rings in case of a corresponding wear-down ( 2 rings at the maximum per stuffing box ) . If no sufficient sealing effect can be obtained by this measure ,then clean and repack the stuffing box . 5.4 Electric Motors Electric motors supplied from us are provided with a bearing grease charge for 2000 hours of operation. Carry out maintenance by following the requirements of the manufacturers of the electric motors .
6.0
Trouble shooting check list Operational Trouble
Number of Code Register
Pump refuses to prime Pump fails to discharge Pump operates irregularly after start-up or discontinues to discharge Discharge flow too small Discharge pressure too low Increased power absorption of the drive Pump runs unsteadily Pump runs hot Leakage through shaft seal Bearings run hot
1 , 2 , 5 , 7 , 10 , 11 3,7 4,5,6,7 5 , 6 , 7 , 10 , 11 , 16 , 17 , 23 , 25 , 26 5 , 8 , 11 , 14 , 15 , 17 , 23 , 25 , 26 8 , 9 , 10 , 12 , 14 , 17 , 22 , 24 , 31 7 , 8 , 10 , 12 , 13 , 14 , 17 , 20 , 21 , 25 , 26 13 , 16 , 17 , 19 , 22 , 24 , 31 28 , 29 , 30 , 31 , 32 18 , 19 , 20 , 21 , 27 , 30 , 33 , 34
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
[email protected] Page 4 of 8
6.0
Trouble shooting check list
1 2. 3 4.
Cause Ejector not operable Self-priming stage without operating fluid Pump not sufficiently vented Suction sided piping system insufficiently vented
5.
Suction line or shaft seal leaky
6.
Suction line breathes air
7.
Suction lift too high (NPSH[of system]to low)
8.
Pump does not operate at its operating point (refer to ordering data and/or rating plate) Conveying medium fails to coincide with ordering data Wrong sense of rotation Speed too slow Speed too high Discharge flow insufficient
9. 10. 11. 12. 13.
14. Discharge flow to high 15. Discharge head insufficient
16. Resistances of system too high 17. Unfavourable influence due to parallel operation or because of branches 18. Pumping set inadequately aligned 19. Pump stressed during installation 20. Misalignment and/or untrue revolving of shaft 21. Imbalance of rotor 22. Sealing rings discolour 23. Sealing rings worn down 24. Rotor is rubbing on casing 25. Impeller damaged 26. Clogging in piping system and/or in impeller 27. Increased axial thrust 28. Damage to mechanical gland seal owing to dry running 29. Mechanical gland seal fitting faulty 30. Sealing fluid/cooling fluid supply insufficient 31. Stuffing box obliquely or tightened too strongly 32. Shaft seal worn 33. Bearings filled with too much grease 34. Bearings defective
Remedy Check control voltage and compressed air supply Fill up pump and switch same to "Ansaugen" Evacuate or fill up pump with conveying medium Draw off air pockets . Shut off lateral branches of piping system Check shaft seal , pressure test suction line , shut off branch pipes of system Medium covering on suction pipe inlet to be checked increased Check arrangement or resistances of suction system . Fully open all suction sided fittings . Clean filters . Examine piping for clogging . Regulate operating point via discharge sided regulating device and/or orifice plate Consult us (Specific gravity and viscosity)
Check drive , change terminals of electric motor Check drive Check drive Check system resistances , open shut-off fittings and/or examine terminals . Check system for possible clogging Regulate operating point Check system resistances , fully open all fittings , clean piping system and filters , remove foreign bodies Refer to item 13 Check system Check seating and stress-free connection of piping Realign! Check for and eliminate stresses from pipe lines and seating Shaft and check for alignment Balance rotor Refer to item 19 . Check and regulate operating point Replace rings Refer to items 19 and 20 . Examine bearing arrangement Recondition or replace impeller Remove deposits and/or foreign bodies from within pipe and pump Check operating point . Check equalising holes of impeller Replace mechanical gland seal Check fitting arrangement Check pipe lines and pressure and/or supply Correct tightening torque Repack , or replace mechanical gland seal Remove surplus grease Replace bearings
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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7.0
Maintenance and Inspection schedule (Interval Periods) Works to be carried out Stuffing box Retightening Adding of packing rings or repacking Replacement of shaft sleeves Mechanical Gland Seal Replacement of same
8.0
Interval Period(Hours)
250 2000 12000
8000
Rolling Contact Bearing Regreasing Replacement
siehe 5.1 20000
Coupling Checking the packages
12000
Inspection Verification of revolving clearances
12000
Description of the Priming Pump (Liquid Seal Pump)
The liquid seal priming pump consists of the air pump housing and bladed air pump impeller . The bladed impeller is mounted on the same shaft as the rotor . It is fitted into the air pump housing but with sufficient clearance to prevent wear of the housing walls . After the priming pump has been primed with the medium to be handled , a ring of liquid is formed in the pump housing as a result of the centrifugal force set up by the rotation of the bladed impeller , and a sickle-shaped working space is formed around the hub of the impeller . This working space is divided by the blades into individual chambers , the liquid ring being first enlarged and then reduced during rotation . With cubical expansion the air or the liquid is drawn in through the suction slot , and with cubical contraction it is ejected through the pressure slot . The air pump is set in such a way that it can withdraw from the rear of the rotor through ducts provided for the purpose , the control cock being set to "Ansaugen"(suction) . At first , an air/water mixture is forcefully ejected ; this continues until a regular flow of water establishes itself . The pump is now filled with water and delivery starts automatically . This is the end of the priming period , the control cock is set to "Betrieb"(operation) and the water drawn in is constantly circulated through the pump .
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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9.0
Alignment for flexible coupling
Straight edg e
When aligning the coupling halves, the angular and parallel offset misalignments of shafts relative to each other should be as small as possible. Alignment to be carried out in two planes as shown in fig. 1.1 with a straight edge (offset misalignment) and spacer bar (angular misalignment). A dial indicator will give greater accuracy.
Gap gauge Fig. 1.1
Axial movement
Coupling size
Angular misalignment
∅
S mm
58 68 80 95 110 125 140 160 180 200 225
5 5 5 5 5 5 5 6 6 6 6
Perm. Deviation mm
+1 +1 +1 +1 +1 +1 +1 +1 +1
Offset misalignment
Angular misalignment Kw S max – S min mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Offset misalignment Kr Mm 0,10 0,11 0,13 0,15 0,18 0,21 0,24 0,27 0,30 0,34 0,38
Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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Heinrich Behrens Pumpenfabrik - Von-Thünen-Str. 7 - D-28307 Bremen Tel.: 49 (0)421 4 86 81-0 - Fax: 49 (0)421 4 86 81 11 - email:
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TYP/TYPE ASED-C
PD-ASED C-11-BEHRENS-GB.DOC
Table of contents 1 Installation 2
Commissioning
3
Maintenance and repair
3.1 Spare parts 3.2 Disassembly and assembly of the vacuum pump
Operating voltage Protection Nominal pressure Weight Frequency Suction capacity * Rotations Power input *
V IP PN kg Hz l / min -1 min kW
4
Appendix
4.1 4.2 4.3 4.4 4.5
Dimensions Installation example Disturbances Circuit diagram Fittings
115 / 230 54 10 17 50 145 3000 0,3
60 170 3600 0,4
aspirated gas, refered to air (15°C, 1013mbar) Pressure-Stage: Switch-on Point Switch-off Point
bar bar Material: Bronze (G-CuAl10Ni) Bronze (G-CuAl10Ni) Stainless steel (X6CrNiTi1810) Bronze (G-CuSn10) Steel galvanized NBR Connections: Venting Exhaust, Drainage Pressure Switch
U 0,3 0,5
V 0,6 1,1
W 1,1 1,6
Pump casing Pump impeller Control disc Valve Tank Sealings
A B C
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TYP/TYPE ASED-C
1.
PD-ASED C-11-BEHRENS-GB.DOC
Installation instructions Caution
Fundamentally every ventilating pipe is to be installed ascending from the ventilating point to the priming unit. As a indication for selecting the nominal size of the ventilating pipes please refer to the respective connection size at the priming unit. The suction system has to be installed above the highest ventilating point. In case of water as pumping media the maximum installation height over the lowest intake-sided liquid level must not exceed 8 m, minus the dynamical losses of the suction system. The evacuation occurs via pipes to be installed ascending to the connection A. The service liquid tank must be filled up for the first start up via connection B. Via the exhaust connection B the aspirated air escapes. Back pressure must be avoided. Small quantity of liquid can escape from time to time. Service liquid: The liquid ring vacuum pumps require suitable liquid such as water during operation. The service liquid must not tend to bubbles and must not attack the components of the pump. The vacuum pump is supplied by an attached service liquid tank, which has to be filled with adequate service liquid before first commissioning. 2. Commissioning For commissioning pay attention to following steps: -
Check all pipe connections and pipes for proper lay and leakage.
-
Check all electrical connections.
-
Fill up the service liquid tank with adequate medium via connection B Caution Operation of the vacuum pump without service liquid is not permitted and cause damage.
-
Direction of rotation control of the vacuum pump. Switch on the vaccum pump shorthly and check the direction of rotation of the vacuum pump by using the rotation arrow. Caution
Abweichungen bei Sonderausführungen beachten. 3.
Please pay attention to modification for special design.
Maintenance and repair
The priming unit operates with slightly maintenance work. Following inspections respectively work should be performed in fixed intervals which depend on pumping medium, operation mode and operation time. -
Check all components for proper function
-
Check the shaft seal of the vacuum pump through a leakage opening on the upper part of the vacuum pump casing.
3.1 Spare parts A set of sealings including the mechanical seal and the casing seal is available as spare part no. 50 48. 3.2 Disassembly and assembly of the vacuum pump The vacuum pump can be assembled / dismantled as shown in the following scheme.
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TYP/TYPE ASED-C
PD-ASED C-11-BEHRENS-GB.DOC
Before starting work, the vacuum pump must be switched to a power off mode. Starting torque for the thread connections are to be taken from the corresponding DIN-Norm. Caution If sealing compound has been used on the centring rims of the motor end shields, any compound residues must be removed. To assemble the vacuum pump, moisten the centring rims with liquid sealing compound or apply a bead of compound and join the parts together immediately. It is only rarely necessary to dismantle the port plate from the pump cover, e.g. in order to clean or replace parts inside the cover. If the port plate is loosened eithet intentionally or accidentally during dismantling, any residues of old sealing compound must be removed. To assemble the port plate, moisten the seat inside the cover with liquid sealing compound, then fit the port plate into the cover immediatley and press it firmly for approximately 5 seconds. Be careful not to block the service liquid hole or the cavitation protection hole with the sealing compound (visual inspection). Make sure you assemble the impeller in the correct position! Align the blade radii on the casing side! The impeller must sit loosely on the shaft! Cover over the featherkey way when assembling the mechanical seal! The pump section must be dismantled and the shaft supported in order to press on the fan impeller. Lock all screws with adequate srew lock compound.
3
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TYP/TYPE ASED-C
4.
PD-ASED C-11-BEHRENS-GB.DOC
Appendix
4.1 Dimensions
14511b/A4 4.2 Installation example
14514c/A4
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TYP/TYPE ASED-C
PD-ASED C-11-BEHRENS-GB.DOC
4.3 Disturbances Disturbance
Cause
Remedy
Motor doesn't start; no motor noise
At least two of the power supply leads are interrupted One of the supply leads is interrupted Pump is jammed
Check the fuses, terminals and supply leads
Motor doesn't start; humming noise
Pump jammed
Motor circuit-breaker trips when the motor is switched on
The impeller is stuck The impeller is defective Motor bearing defective Winding short-circuit Motor overloaded Counterpressure in discharge too high Too much liquid compressant entrained Pump stuck
Pump doesn't generate vacuum
No service liquid Severe leak in the system Wrong direction of rotation
Pump produces to little vacuum
Pump too small Service liquid supply too low Service liquid too warm (>15°C)
Abnormal noises Pump leaking
5
Slight leak in the system Slide ring packing leaking Pump cavitation Service liquid supply too high Gaskets, seal
Check the fuses, terminals and supply leads Turn the pump impeller, draining and cleaning it if necessary or see also under "Pump jammed" See "Motor doesn't start; huming noise" Replace the impeller Replace bearing Check the motor winding Reduce the service liquid supply Reduce the counterpressure Reduce quantity of compressant See under "Motor doesn't start; humming noise" or "Pump jammed" Check service liquid supply Repair any leaks in the system Revers the direction of rotation by changing over two of the leads Use a bigger pump Increase service liquid supply to maximum value (2.5 times nominal value) Cool the service liquid supply or increase the service liquid supply Repair the leak in the system Check the slide ring packing Open the cavitation protection screw Check the service liquid supply and reduce it Check all gaskets and seal
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4.4 Circuit diagram
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Typ/ Type VEP
Vakuumgesteuertes Absperrventil Vacuum controlled Shut-Off Valve
Fig.1
40401
3
Fig.2
Verwendung:
Application:
Selbsteuerndes kombiniertes Kugelrückschlag- und Entlüftungsventil zur Absaugung von Luft und Gasen aus Rohrleitungen und Behältern mit innerem Unterdruck oder Überdruck (max. 2 bar) mittels einer Evakuierungspumpe.
Self controlled combinated ball type non return and deaeration valve to exhaust air and gas from pipes and vessels under vacuum or pressure (max. 2 bar) conditions by means of a vacuum pump.
Bauart:
Design:
Doppelwirkendes Kugelrückschlagventil mit schwimmender Double-acting ball non return valve with swimming valve ball Ventilkugel und vakuumgesteuertem Kolbenantrieb. and vacuum operated control piston. Nenndruck:
Nominal Pressure:
PN 10.
PN 10.
Werkstoffe:
Materials:
Gehäuse Ventilkugel Kolben Ventilsitz
GCuSn10 Polyamid PP/PE NBR
Einbauhinweis:
Vertikal, Durchfluß in Pfeilrichtung. Anschluß "A" muß standig offen sein.
Casing Valve ball Piston Valve seat
Bronze ( GCuSn10) Polyamide PP/PE NBR
Installation:
Vertical, flow in arrow direction Connection "A" must be opened permanently.
A B C D E F G
VEP 3/4" G 1/4" G 3/4" G 3/4" SW 53 92 40 50
VEP 1" G 1/4" G 1" G 3/4" SW 53 92 40 50
VEP 11/2" G 1/4" G 11/2" G 11/2" SW 65 148 74 55
Fig. 3
Sonderausführungen auf Anfrage / Änderungen vorbehalten
Special design upon request / Suject to change
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Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item H1
Service Type: Description
H dro hore um no.1 CR 5-9 F Multi stage inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61366
45 1000 5,00 7,00 7,00 1,80 2,20 3450 1,40
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Stainless steel Stainless steel Rolling contact grease Mechanical seal TC-Carbon EPDM DN 32 32
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : IM V18, IP 55, ISO B : DOL : 440 / 60 : 2,20 : 4,50 : 36,00
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
PTC : SPM : no Space heater : no
Weights
42,00
/
Total
(kg)
: 42,00
16.02.2005
Technical specification HSHI 234
Hyundai Samho Heavy Industries Co., Ltd. 1700 Youngdang-Ri, Samho-Myun Item H1
Service Type: Description
H dro hore um no.2 CR 5-9 F Multi stage inline centrifugal pump
Technical data
Serial no.
Medium Temperature Viscosity Density Capacity Suction pressure Delivery pressure Difference pressure Power consumption Motor required Speed NPSH (r)
(°C) (cst) (kg/cbm) (cbm/h) (bar) (bar) (bar) (kW) (kW) (rpm) (m)
: : : : : : : : : : :
61367
45 1000 5,00 7,00 7,00 1,80 2,20 3450 1,40
Materials
Pump
Bearings Coupling Shaft seal
Casing : Impeller : Wear rings : Shaft : Type : Lubrication : Type : Type : Material :
Connections
suction side : pressure side
Cast iron GG-25 Stainless steel Stainless steel Rolling contact grease Mechanical seal TC-Carbon EPDM DN 32 32
PN 16 16
Prime mover
E-Motor
Type Execution Starting (V / Hz) (kW) (A) (A)
: : IM V18, IP 55, ISO B : DOL : 440 / 60 : 2,20 : 4,50 : 36,00
Pump / e-motor
(kg)
:
Classification
according to GL without certificate
Power supply Power Rated current Starting current
PTC : SPM : no Space heater : no
Weights
42,00
/
Total
(kg)
: 42,00
16.02.2005
CONTENTS
2. Type designation Page
2.1 Pump key for CR, CRI, CRN 1, 3 and 5
1.
Handling
8
2. 2.1 2.2 2.3
Type designation Pump key for CR, CRI, CRN 1, 3 and 5 Pump key for CR, CRN 8 and 16 Pump key for CR, CRN 32, 45, 64 and 90
8 8 8 8
Pump range: CR, CRI, CRN
3.
Applications
8
Number of impellers
4. 4.1 4.2 4.3
9 9 9
Code for pump version
4 .4 4 .5 4.6 4. 7 4.8 4 .9 4 .1 0
Technical data Ambient temperature Liquid temperature Maximum permissible operating pressure and liquid temperature for the shaft seal M in imu m i nl et p re ss ur e M ax imu m i nl et p re ssu re Minimum flow rate Electr ical data Frequency of starts and stops D im en sio ns a nd w eig ht s S ou nd leve l
9 9 10 10 10 10 10 10
5.
Installation
10
Nominal flow rate in m³/h
6. 6.1
Electrical connection Frequency converter operation
11 11
Number of stages x 10
7.
Start-up
11
Number of impellers (is only used if the pump has fewer impellers than chambers)
8.
Maintenance
11
Code for pump version
9.
Frost protection
12
Code for pipework connection
10. 10.1
Service Service kits
12 12
Code for materials
11.
Coupling adjustment
12
12.
Fau lt f ind ing ch ar t
13
13.
Disposal
13
Example Nominal flow rate in m³/h
Code for pipework connection Code for materials Code for rubber pump parts Code for shaft seal
2.2 Pump key for CR, CRN 8 and 16 Example
1. Handling The motors of the CR, CRI, CRN 1, 3, 5 and CR, CRN 8, 16 pumps are supplied with lifting eyes which must not be used for lifting the entire pump. When the entire pump is to be lifted, observe the following:
•
CR, CRI, CRN 1, 3, 5 and CR, CRN 8, 16 pumps fitted with GRUNDFOS MG motors should be lifted in the pump head by means of straps or th e like. CR, CRN 32, 45, 64 and 90 fitted with GRUNDFOS MG motors up to and including 11 kW should be lifted by means of the eye nut fitted to the pump head.
•
CR, CRN 32, 45, 64 and 90 fitted with Siemens motors of 15 kW and up should be lifted by means of th e lifting devices fitted to the motor.
•
For other motor makes than those mentioned above, it is recommended to lift the pump in the pump head by means of straps.
CR 8 - 20 / 2 - X - X - X - XXXX
Pump range: CR, CRN
Code for shaft seal and rubber pump parts
2.3 Pump key for CR, CRN 32, 45, 64 and 90 Example
Before beginning installation procedures, these installation and operating instructions should be studied carefully. The installation and operation should also be in accordance with local regulations and accepted codes of good practice.
CR 3 - 10 X - X - X - X - XXXX
CR 32 - 2 - 1 - X - X - X - X - XXXX
Pump range: CR, CRN Nominal flow rate in m³/h Number of stages Number of impellers with reduced diameter Code for pump version Code for pipework connection Code for materials Code for rubber pump parts Code for shaft seal
3. Applications GRUNDFOS multistage in-line centrifugal pumps, types CR, CRI and CRN, are designed for a wide range of applications. Pumped liquids Thin, non-explosive liquids, not containing solid particles or fibres. The liquid must not attack the pump materials chemically. When pumping liquids with a density and/or viscosity higher than that of water, motors with correspondingly higher outputs must be used, if required. CR, CRI, CRN For liquid transfer, circulation and pressure boosting of cold or hot clean liquids. CRN In systems where all parts in contact with the liquid must be made of high-grade stainless steel, CRN pumps must be used.
8
4. Technical data
Fig. 4 CR, CRN 32, 45, 64 and 90:
4.1 Ambient temperature Maximum +40°C.
p [bar]
If the ambient temperatur e exceeds +40°C or if the motor is located 1000 metres above sea level, the motor output (P2) must be reduced due to the low density and consequently low cooling effect of the air. In such cases, it may be necessary to use a motor with a higher rated output.
35
Fig. 1
10
30
KUBE / KUBV
25
KUBE
20 KUBE / KUBV
E E V U U U U U U K K K
15
KUBE
KUUE / KUUV
5
P2 [%]
0 -40 -20
100
0
20
40
60
80
90
100 120 140 160 t [°C]
0 0 5 4 3 2 9 1 1 0 M T
80
4.4 Minimum inlet pressure
70 60 50 20 25 30 35 40 45 50 55 60 65 70 75 80 t [°C] 1000
2250
3500
m
8 9 5 1 9 8 1 2 0 0 M T
Fig. 5
Hf
Example: Figure 1 shows that P2 must be reduced to 88% when the pump is installed 3500 metres above sea level. At an ambient temperature of 70°C, P2 must be re duced to 78% of the rated output.
H Pb
NPSH
4.2 Liquid temperature See fig. A, page 76, which indicates the relationship between liquid temperature and maximum permissible operating pressure.
Hv
Note: The maximum permissible operating pressure and liquid temperature ranges apply to the pump only.
0 0 8 3 8 1 1 0 2 0 M T
4.3 Maximum permissible operating pressure and liquid temperature for the shaft seal
The maximum suction lift “H” in metres head can be calculated as follows:
Fig. 2
H = p b x 10.2 – NPSH – H f – H v – H s
CR, CRI, CRN 1, 3 and 5:
pb
= Barometric pressure in bar. (Barometric pressure can be set to 1 bar). In closed systems, p b indicates the system pressure in bar.
NPSH
= Net Positive Suction Head in metres head (to be read from the NPSH curve on page 75 at the highest flow the pump will be delivering).
Hf
= Friction loss in suction pipe in metres head at the highest flow the pump will be delivering.
Hv
= Vapour pressure in metres head, see fig. E on page 79. tm = Liquid temperature.
Hs
= Safety margin = minimum 0.5 metres head.
p [bar] 35 30 25 20 HUBE / HUBV
E E V U U U U U U H H H
15 10
HUUE / HUUV
HUBE
5 0 -40 -20
0
20
40
60
80
100 120 140 160 t [°C]
0 0 9 4 9 2 6 0 2 0 M T
If the calculated “H” is positive, the pump can operate at a suction lift of maximum “H” metres head. If the calculated “H” is negative, an inlet pressure of minimum “H” metres head is required. There must be a pressure equal to the calculated “H” during operation.
Fig. 3 CR, CRN 8 and 16: p [bar]
Example:
30
pb = 1 bar. Pump type: CR 16, 50 Hz. Flow rate: 16 m³/h. NPSH (from page 75): 1.5 metres head. Hf = 3.0 metres head. Liquid temperature: +60°C. Hv (from fig. E, page 79): 2.1 metres head.
25 AUUE / AUUV
20 15 10 5
AUUE
AUUE / AUUV E V U U U U R R
BUBE / BUBV
BUBE
0 -40 -20
0
20
40
60
80
100 120 140 160 t [°C]
0 0 5 4 2 2 9 1 1 0 M T
H = p b x 10.2 – NPSH – H f – H v – H s [metres head]. H = 1 x 10.2 – 1.5 – 3.0 – 2.1 – 0.5 = 3.1 metres head. This means that the pump can operate at a suction lift of maximum 3.1 metres head. Pressure calculated in bar: 3.1 x 0.0981 = 0.30 bar. Pressure calculated in kPa: 3.1 x 9.81 = 30.4 kPa.
9
4.5 Maximum inlet pressure
5. Installation
Figure B, page 77, shows the maximum permissible inlet pressure. However, the actual inlet pressure + pressure when the pump is running against a closed valve must always be lower than the “ maximum permissible operating pressure ”.
When installing the pump, follow the procedure below in order to avoid damaging the pump. Step
The pumps are pressure-tested at a pressure of 1.5 times the value stated in fig. B, page 77.
Action
1 0 0 8 3 3 1 0 0 2 0 M T
4.6 Minimum flow rate Due to the risk of overheating, the pump should not be used at flows below the minimum flow rate. The curve below shows the minimum flow rate as a percentage of the nominal flow rate in relation to the liquid temperature. Fig. 6
2
L1 L2
30 20 10 0 40
Page 78 shows: 4xø
Qmin [%] 40
60
80
100 120 140 160 180 t [°C]
0 0 4 3 6 1 8 2 1 0 M T
Note: The pump must never operate against a closed discharge valve.
B1 B2
3 9 3 3 6 5 2 2 0 0 M T
4.8 Frequency of starts and stops Motors up to 4 kW: Maximum 100 times per hour. Oth er moto rs: Maximu m 20 times per hour .
4.10 Sound level See fig. D, page 79.
•
pipework connections and
•
diameter and position of foundation bolts.
5 0 0 8 3 4 1 1 0 2 0 M T
Install the pipes so that air locks are avoided, especially on the suction side of the pump.
In the case of installations in which:
6
0 0 8 3 5 1 1 0 2 0 M T
10
dimensions of the base,
0 0 8 3 6 1 1 0 2 0 M T
See motor nameplate.
See label on the packing.
•
To minimize possible noise from the pump, it is advisable to fit expansion joints either side of the pump and anti-vibration mountings between foundation and pump. Isolating valves should be fitted either side of the pump to avoid draining the system if the pump needs to be cleaned, repaired or replaced. The pump must always be protected against backflow by means of a non-return valve (foot valve).
4.7 Electrical data
Weights:
port-to-port lengths,
7 9 0 4 1 4 2 1 1 0 M T
4
Dimensions: See fig. C, page 78.
•
The pump can be installed vertically or hor izontally. Ensure that an adequate supply of cool air reaches the motor cooling fan. However, the motor must never fall below the horizontal plane.
3
4.9 Dimensions and weights
Arrows on the pump base show the direction of flow of liquid through the pump.
•
the discharge pipe slopes downwards away from the pump,
•
there is a risk of siphon effect,
•
protection against backflow of unclean liquids is necessary, a vacuum valve must be fitted close to the pump.
6. Electrical connection
7. Start-up
The electrical connection should be carried out by an authorized electrician in accordance with local regulations.
Note: Do not start the pump until it has been filled with liquid and vented.
Before removing the terminal box cover and before any removal/dismantling of the pump, make sure that the electricity supply has b een switched off.
Pay attention to the direction of the vent hole and take care to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot-water installations, special attention should be paid to the risk of injur y caused by scalding hot water.
The pump must be connected to an external mains switch with a minimum contact gap of 3 mm in all poles. The operating voltage and frequency are marked on the motor nameplate. Make sure that the motor is suitable for the electricity supply on which it will be used.
Follow the instructions on page 4.
Single-phase GRUNDFOS motors incorporate a thermal switch and require no additional motor protection.
For these pumps, it is advisable to open the bypass valve during start-up. The bypass valve connects the suction and discharge sides of the pump, thus making the filling procedure easier. When the operation is stable, the bypass valve can be closed. When pumping liquids containing air, it is advisable to leave the bypass valve open.
Three-phase motors must be connected to a motor starter. The terminal box can be turned to four positions, in 90° steps: 1. If necessary, remove the coupling guards. Do not remove the coupling. 2. Remove the bolts securing the motor to the pump.
CR, CRI, CRN 1 to 5, CR, CRN 8 and 16:
Fig. 7
3. Turn the motor to the required position. 4. Replace and tighten the bolts. 5. Replace the coupling guards.
Drain plug
The electrical connection should be carried out as shown in the diagram inside the terminal box cover.
Bypass valve
6.1 Frequency converter operation Motors supplied by GRUNDFOS: All three-phase motors supplied by GRUNDFOS can be connected to a frequency converter. Dependent on the frequency converter type, this may cause increased acoustic noise from the motor. Furthermore, it may cause the motor to be exposed to detrimental voltage peaks. Note: GRUNDFOS motors types MG 71 and MG 80 as well as MG 90 (1.5 kW, 2-pole), all for supply voltages up to and including 440 V (see motor nameplate), must be protected against voltage peaks higher than 650 V (peak value) between the supply terminals. It is recommended to protect all other motors against voltage peaks higher than 850 V. The above disturbances, i.e. both increased acoustic noise and detrimental voltage peaks, can be eliminated by fitting an LC filter between the frequency converter and the motor. For further information, please contact the frequency converter or motor supplier. Other motor makes than those supplied by GRUNDFOS: Please contact GRUNDFOS or the motor manufacturer.
7 9 0 4 3 4 2 1 1 0 M T
8. Maintenance Before starting work on the pump, make sure that all power supplies to the pump have been switched off and that they cannot be accidentally switched on. Pump bearings and shaft seal are maintenance-free. If the pump is to be drained for a long period of inactivity, remove one of the coupling guards to inject a few drops of silicone oil on the shaft between the pump head and the coupling. This will prevent the shaft seal faces from sticking. Motor bearings: Motors which are not fitted with grease nipples are maintenancefree. Motors fitted with grease nipples should be lubricated with a hightemperature lithium-based grease, see the instructions on the fan cover. In the case of seasonal operation (motor is idle for more than 6 months of the year), it is recommended to grease the motor when the pump is taken out of operation.
11
9. Frost protection Pumps which are not being used during p eriods of frost should be drained to avoid damage. Drain the pump by loosening the vent screw in the pump head and by removing the drain plug from the base. Care must be taken to ensure that the escaping water does not cause injury to persons or damage to the motor or other components. In hot-water installations, special attention should be paid to the risk of injury caused by scalding hot water. Do not tighten the vent screw and replace the drain plug until the pump is to be used again. CR, CRI, CRN 1 to 5, CR, CRN 8 and 16: Before replacing the drain plug in the base, screw the bypass valve out against the stop, see fig. 7. Fit the drain plug by tightening the large union nut followed b y the bypass valve.
10. Service Note: If a pump has been used for a liquid which is injurious to health or toxic, the pump will be classified as contaminated. If GRUNDFOS is requested to service the pump, GRUNDFOS must be contacted with details about the pumped liquid, etc. be- fore the pump is returned for service. Otherwise GRUNDFOS can refuse to accept the pump for service. Possible costs of returning the pump are paid by the customer. However, any application for service (no matter to whom it may be made) must include details about the pumped liquid if the pump has been used for liquids which are injurious to health or toxic.
10.1 Service kits Service kits for CR, CRI and CRN, see www.grundfos.com.
11. Coupling adjustment For adjustment of coupling in CR, CRI, CRN 1 to 5, see fig. F, page 80. For adjustment of coupling in CR, CRN 8 and 16, see fig. G, page 81. For adjustment of coupling in CR, CRN 3 2 to 90, see fig. H, page 82.
12
12. Fault finding chart Before removing the terminal box cover and before any removal/dismantling of the pump, make sure tha t the electricity supply has been switched off and that it cannot be accidentally switched on. Fault
Cause
Remedy
1. Motor does not run when started.
a) Supply failure.
Connect the electricity supply.
b) Fuses are blown.
Replace fuses.
c) Motor sta rte r o ver loa d has tr ippe d out.
Re act ivat e the m otor pr otection.
d) Thermal protection has tripped out.
Reactivate the thermal protection.
e) Main contacts in motor starter are not making contact or the coil is faulty.
Replace contacts or magnetic coil.
f)
Repair the control circuit.
Control circuit is defective.
g) Motor is defective.
Replace the motor.
a) One fuse/automatic circuit breaker is blown.
Cut in the fuse.
b) Contacts in motor starter overload are faulty.
Replace motor starter contacts.
c) Cable connection is loose or faulty.
Fasten or replace the cable connection.
d) Motor winding is defective.
Replace the motor.
e) Pump mechanically blocked.
Remove the mechanical blocking of the pump.
f)
Overload setting is too low.
Set the motor starter correctly.
3. Motor starter overload trips out occasionally.
a) Overload setting is too low.
Set the motor starter correctly.
b) Low voltage at peak times.
Check the electricity supply.
4. Motor starter has not tripped out but the pump does not run.
a) Check 1 a), b), d), e) and f).
5. Pump capacity not constant.
a) Pump inlet pressure is too low (cavitation).
Check the suction conditions.
b) Suction pipe/pump partly blocked by impurities.
Clean the pump or suction pipe.
c) Pump draws in air.
Check the suction conditions.
a ) Su ct io n p ip e/ pu mp blo ck ed by im pu rit ie s.
C le an th e p um p o r s uct io n p ip e.
b) Foot or non-return valve blocked in closed position.
Repair the foot or non-return valve.
c) Leakage in suction pipe.
Repair the suction pipe.
d) Air in suction pipe or pump.
Check the suction conditions.
e ) Motor r otate s in th e wr ong dire ct ion .
Cha nge the dir ection of r otation of the moto r.
7. Pump runs backwards when switched off.
a) Leakage in suction pipe.
Repair the suction pipe.
b) Foot or non-return valve is defective.
Repair the foot or non-retur n valve.
8. Leakage in shaft seal.
a) Shaft seal is defective.
Replace the shaft seal.
9. Noise.
a) Cavitation occurs in the pump.
Check the suction conditions.
b) Pump does not rotate freely (frictional resistance) because of incorrect pump shaft position.
Adjust the pump shaft.
c) Frequency converter operation.
See section 6.1 Frequency converter operation .
2. Motor starter overload trips out immediately when supply is switched on.
6. Pump runs but gives no water.
13. Disposal Disposal of this product or parts of it must be carried out according to the following guidelines: 1. Use the local public or pr ivate waste collection service. 2. In case such waste collection service does not exist or cannot handle the materials used in the product, please deliver the product or any hazardous materials from it to your nearest GRUNDFOS company or service workshop.
Subject to alterations.
13
Service instructions CR 1, CR 3 and CR 5 Model A 50/60 Hz 1/3~
Table of contents 1.
Type identification........................................................................................................................... 2
1.1
Nameplate CR-, CRI, CRN, 1, 3 and 5 .............................................................................................. 2
1.2
Type key ............................................................................................................................................ 3
1.3
Codes used........................................................................................................................................ 3
2.
Torques and lubricants ................................................................................................................... 4
3.
Service tools .................................................................................................................................... 5
3.1
Special tools ...................................................................................................................................... 5
3.2
Standard tools.................................................................................................................................... 5
3.3
Torque tools....................................................................................................................................... 6
4.
Dismantling and assembly ............................................................................................................. 7
4.1
General .............................................................................................................................................. 7
4.2
Replacement of motor ....................................................................................................................... 8
4.3
Replacement of shaft seal ................................................................................................................. 9
4.4
Dismantling and assembly of pump main parts ............................................................................... 10
4.5
Dismantling and assembly of chamber stack .................................................................................. 11
4.6
Dismantling and assembly of base and pump head ........................................................................ 12
4.7
Checking and replacement of parts ................................................................................................. 14
4.8
Order of assembly for chambers and impellers ............................................................................... 15
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Page 1 of 16
1. Type identification This section shows the type key, the nameplate and the codes that can appear in the variant code. Note: As codes can be combined, a code position may contain more than one code (letter).
1.1 Nameplate CR-, CRI, CRN, 1, 3 and 5 2 3
1
6 7 8 9 10
4 5
CR1-3 A-A-A-E-HUBE Type Model A96450484P30047 kW 60Hz P2 0.37 kW 50Hz P2 0.37 n 2900 min-1 n 3500 min-1 Hmax18.4 m Hmax26.8 m 3 3 Q 2.0 m/ h Q 2.1 m /h H 12.7 m H 20.4 m o max max 16/120 bar / C CCW MADE IN DENMARK
0 2 8 9 3 4 6 9
16 18
0 0 8 4 6 9 4 0 2 0 M T
Description
Pos.
17
Pos.
11 12 13 14 15
Description
1
Type designation
10
Head at rated flow rate, 50 Hz
2
Model
11
P2, 60 Hz
3
Product number
12
Speed, 60 Hz
4
Place of production
13
Head against closed valve, 60 Hz
5
Production year and week
14
Rated flow rate, 60 Hz
6
P2, 50 Hz
15
Head at rated flow rate, 60 Hz
7
Speed, 50 Hz
16
Maximum pressure and temperature
8
Head against closed valve, 50 Hz
17
Country of production
18
Direction of rotation (CCW = counterclockwise)
9
Rated flow rate, 50 Hz
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Page 2 of 16
1.2 Type key Example
CR
3-
10
X-
X-
X-
X-
XXXX
Type range Rated flow rate in m³/h Number of impellers Code for pump version a) Code for pipe connection b) Code for pump materials c) Code for rubber parts d) Code for shaft seal e)
1.3 Codes used Note
Code
Description
A
Basic version
U
NEMA version
A
Oval flange
a
b FGJ c
DIN-, ANSI- and JIS flange
A
Pump head and base: cast iron Other wetted parts: stainless steel DIN W.-Nr. 1.4301
E
EPDM
V
FKM
d
HUBE/V
Balanced cartridge seal; rotating face: tungsten carbide; stationary seat: synthetic resin-impregnated carbon; O-rings, see note d
HUUE/V
Balanced cartridge seal; rotating face: tungsten carbide; stationary seat: tungsten carbide; O-rings, see note d
e
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Page 3 of 16
2. Torques and lubricants This section shows the screws and nuts that must be tightened to a certain torque and the lubricants to be used. Pos. 7.a
9
Description Screw
Hexagon socket head screw
Number
Dim.
Torque [Nm]
4
M4
2
M6
13
M8
31
M10
62
4
18
Air vent screw (spindle)
1
½” (M8)
35 (3)
23
Plug
1
½”
35
25
Priming valve (spindle)
1
½” (M10)
35 (5)
26
Staybolt
4
M12
28
Hexagon head screw
4
Lubricant
Thread-Eze
Soapy water
Thread-Eze
M6
10
M8
12
M12
40
Thread-Eze
35
Hexagon head screw
4
M10
23
Thread-Eze
36
Nut
4
M12
50
Thread-Eze
37
O-ring
2
ø137,5 x 3,3
Rocol 22
See section 4.8 Order of assembly for chambers and impellers .
Rocol 22
47.a
Bearing ring
67
Lock nut
1
M8
18
105
Shaft seal
1
M28
35
113
Hexagon socket set screw
3
M5
2,5
Thread-Eze, part no. SV9997 (0,5 l). Bonderlube, part no. SV9995 (1 l). Rocol 22, part no. RM2924 (1 kg).
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Page 4 of 16
Bonderlube
3. Service tools The following drawings and tables show special, standard and torque tools for pump service.
1 0 4 0 6 4 8 0 2 0 M T
3.1 Special tools Pos. A B C D E F G
Description Shaft holder for assembly Tubular box spanner for shaft seal Puller Circlip pliers (not used for CR) Tool for outer sleeve Tool for corrugated spring Tool for O-ring
For pos.
Suppl. information
Part no. SV0040
105
SV2007
65
SV0239 SV2014 V7170478 V7170227 V7170230
55 60 37
3.2 Standard tools Pos. H
Description Bit holder
PZ2 5 6 8
I
Bits kit
J
Hexagon socket bit
K
Ring/open-end spanner
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Bit no.
GB
For pos. I-J 7.a 9-H 113-H-M 28 28-67 35 28-36 18-23-25
Suppl. information 1/4” 1/4” M6 - 5 mm 1/4” M8 - 6 mm 1/4” M10 - 8 mm 1/4” M5 - 2,5 mm 1/4” M6 - 10 mm M8 - 13 mm M10 - 17 mm M12 - 19 mm M16 - 24 mm
Page 5 of 16 6
Part no. SV2011
SV2010
SV2012 SV0083 SV0055 SV0056 SV0054 SV0122
3.3 Torque tools Pos.
Description
For pos.
L
Torque wrench
M N
Torque screwdriver Ratchet insert tool
O
Ring spanner
P
Socket driver for hexagon socket head screws
9-N
Q
Socket spanner, purpose-ground
67-L
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N-O J L-O-P 28-L 28-L 28-L 36-L 18-23-25-L
Suppl. information 4-20 Nm 9 x 12 20-100 Nm 9 x 12 40-200 Nm 14 x 18 1-6 Nm 1/4” 9 x 12 -> 1/2” M6 - 10 mm 9 x 12 M8 - 13 mm 9 x 12 M10 - 17 mm 9 x 12 M12 - 19 mm 9 x 12 M16 - 24 mm 9 x 12 M6 - 5 mm ½” x ½” M8 - 6 mm ½” x ½” M10 - 8 mm ½” x ½” M8 - 13 mm 9 x 12
Page 6 of 16 6
Part no. SV0292 SV0269 SV0400 SV0438 SV0295 SV0310 SV0294 SV0270 SV0271 SV0524 SV0296 SV0297 SV0298 SV2013
4. Dismantling and assembly 4.1 General If it is necessary to dismantle the pump, either because it is choked or damaged, please follow the instructions in the following sections. Position numbers of parts (digits) refer to drawings and parts lists; position numbers of tools (letters) refer to section 3. Service tools . Before dismantling the pump: •
Disconnect the electricity supply to the motor.
•
Close the isolating valves, if fitted, to avoid draining the system.
•
Remove the electric cable in accordance with local regulations.
•
Note the centre of gravity of the pump to prevent it from overturning. This is especially important in the case of long pumps.
Before assembly: •
Clean and check all parts.
•
Replace defective parts by new parts.
•
Order the necessary service kits.
•
Gaskets and O-rings should always be replaced when the pump is overhauled.
During assembly: •
Lubricate and tighten screws and nuts to correct torque as stated in section 2. Torques and lubricants .
After assembly: •
The pump should be tested according to the test specifications 96446769.
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Page 7 of 16 7
4.2 Replacement of motor 4.2.1 Dismantling 1. Remove the screws pos. 7.a together with the coupling guards pos. 7. 2. Remove the screws pos. 9 together with the coupling halves pos. 10.a and the shaft pin pos. 10. 3. Remove the screws pos. 28. 4. Lift the motor off the pump head pos. 2. 4.2.2 Assembly 1. Fit the motor to the pump head. 2. Fit the screws pos. 28 and tighten diagonally to the correct torque. 3. Insert the shaft pin pos. 10 into the shaft hole. 4. Fit the coupling halves pos. 10.a on the shaft and fit the screws pos. 9. Tighten the screws and leave loose. Check that the gaps either side of the coupling halves are equal. 5. Tighten screws pos. 9 diagonally to the correct torque. Check that the gaps either side of the coupling halves are equal, see Fig. 1
Fig. 1
6. Fit the coupling guards pos. 7 and the screws pos. 7.a.
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Page 8 of 16
4.3 Replacement of shaft seal 4.3.1 Dismantling 1. Remove the motor and the coupling according to the instructions in section 4.2.1. 2. Slacken the three screws pos. 113 by approx. a ¼ of a turn so that the shaft seal is just free of the shaft. 3. Slacken the shaft seal pos. 105 using the box spanner pos. B until the thread is completely free of the pump head. 4. Pull the shaft seal off the shaft. 4.3.2 Assembly 1. If necessary, clean and smooth the shaft end using the holder with emery cloth supplied with the shaft seal kit. 2. Moisten the shaft end with soapy water. 3. Place the shaft seal in the box spanner pos. B and press it down on the shaft. 4. Screw the shaft seal into the pump head and tighten it to the correct torque. 5. Insert the shaft pin pos. 10 into the shaft hole and fit the coupling halves pos. 10.a on the shaft. Fit the screws pos. 9, tighten and leave loose. Check that the gaps either side of the coupling halves are equal. See Fig. 1. 6. Fit the motor to the pump head 7. Fit the screws pos. 28 and tighten diagonally to the correct torque. 8. Insert a suitable screwdriver between the bottom of the coupling and the shaft seal, and raise the shaft/ the coupling against stop, see Fig. 2 .
x x 5 . 0
Fig. 2
0 0 6 4 2 6 4 0 2 0 M T
9. Lower the shaft/the coupling to half that height, see Fig. 2 10.Hold the shaft/the coupling in the position of step 9. and tighten the four screws in the coupling pos. 9 to the correct torque. Check that the gaps either side of the coupling halves are equal, see Fig. 1 11.Tighten the three screws pos. 113 to the correct torque. 12.Fit the coupling guards pos. 7 and the screws pos. 7.a.
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Page 9 of 16 9
4.4 Dismantling and assembly of pump main parts 4.4.1 Dismantling 1. Remove the shaft seal according to the instructions in section 4.3.1. 2. Remove the screws pos. 36 together with the washers pos. 66.a. 3. Loosen the pump head pos. 2 with a light blow on the edge and lift it free of the staybolts pos. 26. The top guide vanes pos. 50.a may stick to the pump head. 4. Loosen the top guide vanes pos. 50.a with a light blow of a rubber mallet if it was not removed with the pump head. 5. Remove the outer sleeve pos. 55. 6. Lift the chamber stack off the base. If the bottom chamber pos. 5.a is removed with the chamber stack, loosen it from the chamber stack; otherwise loosen it from the base pos. 6. 4.4.2 Assembly 1. Fit the chamber stack in the base. The smooth shaft end must be upwards. 2. Fit the outer sleeve pos. 55 in the base and press it home in the base using the tool pos. E. The O-ring pos. 37 must be lubricated, see section 2. Torques and lubricants. 3. Press the top guide vanes into the recess of the top chamber. 4. Fit the pump head on the pump with the air vent screw pos. 18 in the direction required. The O-ring pos. 37 must be lubricated, see section 2. Torques and lubricants. 5. Lubricate the threads of the staybolts, see section 2. Torques and lubricants . 6. Fit the washers pos. 66.a and the nuts pos. 36. 7. Tighten the nuts pos. 36 diagonally to the correct torque.
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Page 10 of 16 10
4.5 Dismantling and assembly of chamber stack 4.5.1 Dismantling 1. Remove the chamber stack according to the instructions in section 4.4.1. 2. Place the shaft holder pos A in a vice, but do not tighten the vice. 3. Fit the shaft pin pos. 10 into the shaft and place the chamber stack in the shaft holder pos. A, see Fig. 3 . Tighten the vice.
Fig. 3
1 0 5 0 6 5 0 1 2 0 M T
4. Remove the nut pos. 67, the washer pos. 66 and the clamp pos. 64.c. 5. Remove the chamber stack components: impeller, chamber, bearing ring and spacing pipe, see section 4.8 Order of assembly for chambers and impellers . 4.5.2 Assembly 1. Place the shaft holder pos A in a vice, but do not tighten the vice. 2. Fit the shaft pin pos. 10 into the shaft and place the shaft in the shaft holder pos. A. Tighten the vice. 3. Fit the components on the shaft: impeller, chamber, spacing pipe and bearing ring, see section 4.8 Order of assembly for chambers and impellers . 4. Fit the clamp pos. 64.c, the washer pos. 66 and the nut pos. 67. Tighten to the correct torque. The washer pos. 66 consists of two washers glued together. If they have been separated, make sure that they are fitted correctly, see Fig. 4..
Fig. 4
1 0 5 0 7 5 0 1 2 0 M T
5. Slacken the vice and remove the chamber stack and the shaft pin pos. 9. 6. Place the bottom chamber pos. 5.a on the chamber stack.
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Page 11 of 16 11
4.6 Dismantling and assembly of base and pump head 4.6.1 Dismantling of base 1. Remove the staybolts pos. 26 from the base pos. 6. 2. Remove flange connections, if any: Oval flange: Remove the screws, pos. 35, the flange pos. 12 and the gasket pos. 39. 3. Remove the priming valve pos. 25 and the O-ring pos. 38. 4. Remove the O-ring pos. 37. 4.6.2 Dismantling of pump head 1. Remove the air vent screw pos. 18, the plug pos. 23 and the O-ring pos. 100. 2. Remove the O-ring pos. 37. 3. Remove the corrugated spring pos. 60.
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Page 12 of 16 13
4.6.3 Assembly of base 1. Fit the O-ring pos. 37 using the tool pos. G, see Fig. 5 .
Fig. 5
1 0 5 0 5 5 0 1 2 0 M T
2. Fit the flange connection, if any: Oval flange: Fit the gasket pos. 39, the flange pos. 12 and the screws, pos. 35. 3. Lubricate the threads of the staybolts, see section 2. Torques and lubricants , and fit the staybolts in the base pos. 6. Tighten the staybolts using your fingers. 4. Fit the O-ring pos. 38 on the priming valve pos. 25 and fit the valve into the base. 4.6.4 Assembly of pump head 1. Fit the O-rings pos. 100 on the air vent screw pos. 18 and the plug pos. 23. Fit the screw and the plug into the pump head. 2. Fit the corrugated spring pos. 60 in the pump head using the tool pos. F, see Fig. 6
Fig. 6
0 0 6 4 2 6 4 0 2 0 M T
3. Fit the O-ring pos. 37 using the tool pos. G, see Fig. 5 .
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Page 13 of 16 13
4.7 Checking and replacement of parts
•
Checking
Replacement
Impeller and neck ring
Neck ring/retainer for neck ring
Check Check whether whether it is necessary necessary to replace impeller due to friction between the neck ring and the impeller skirt.
1. Prise the retainer for for neck ring pos. 65 up and free of the chamber using the puller pos. C.
If wear has caused a noticeable (use a finger nail) groove in the impeller skirt, the impeller should be replaced.
3. Place a new new neck ring on the chamber. chamber. See Fig. 7 .
Neck rings and retainers for neck rings should always be replaced when the chamber stack is dismantled.
2. Remove the neck ring pos. 45.
4. Press a new new retainer for neck ring down on the neck ring and into the chamber. chamb er. It must be possible to move the neck ring freely (sideways) between the retainer and the chamber.
Bearing rings •
If the there re is a visible visible and noticeab noticeable le (use (use a finger finger nail) edge on the rotating bearing ring, both bearing rings should be replaced.
•
Replace Replace the the c chamber hamber with bearing ring pos. 4.a and the rotating bearing ring pos. 47.a.
1 0 6 0 2 8 1 1 2 0 M T
Fig. 7
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Page 14 of 16 14
4.8 Order of assembly for chambers and impellers The assembly of the chamber stack is illustrated in the tables by symbols.
CR / CRI / CRN 1 & 3 2
3
4
5
6
7
8
9
10
11
12
13
15
17
19
21
23 25
27
29
30
31
33
36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
64
64
47a
67
66 4
4
4a
64c
64a 49
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49
Page 15 of 16 16
49
1 0 7 1 5 4 4 0 2 0 M T
CR / CRI / CRN 5 2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
20
22
24
26
29
32
36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
4
4
47a
4a
4a
64
64
64a
64a
49
49
49
49
69
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47a
GB
69
Page 16 of 16 16
67
67
66
66
64c
64c 64d
49
49 0 0 6 4 4 4 4 0 2 0 M T
CR 5-9 - Pro du ct No.: 96448720 96448720
2 8
9
28
10a
7
10
18 100
109
60
105
50a 51 69 49 65 4
37
45
55 64 64a 80
65 4a
45
47a 64d 65 5a
45
64c 66
37
67
25 38 6
1/1
CR 5-9 - Pro du ct No.: 96448720 96448720
50a
36a
10a 8
51
9 10 69
49
113 105
64 109
7a 65
2
7
2 100
45
18
28
23
4
100 36
28
66a 7 76a 7a
49
76
64 80
65 26
60
45
4
37
49
64a
65 45
4a
47a
49 64d 64c 66 67 65 45
5a
55
37
37
6 6
25 38 38
35
12
39
25
1/1
Part List Li st CR 5-9 - Product Prod uct No.: 964487 96448720 20 Po s -
6 25 38
37
2 7 7.a -
8 9
10
Des c r i p t i o n Motor Base complete Base Drain plug with bypass valve O-ring
O-ring
Pump head complete Pump head Coupling guard Screw Coupling complete Hexagon socket head screw
Shaft pin
10.a 18 23 28
Coupling half Air vent screw Pipe plug Hexagon head screw
36 37
Nut O-ring
60
Corrugated spring
66.a
Washer
100
O-ring
26
Staybolt
55
Outer sleeve
-
76 76.a 80 4
-
45 65 4.a
-
45 65 5.a
Nameplate Rivet Chamber stack Chamber complete Ch Chamber Neck ring Neck ring retainer Chamber with bearing ring Ch Chamber Neck ring Neck ring retainer Chamber, bottom Ch Chamber Neck ring Neck ring retainer Bearing ring Impeller
45 65 47.a 49
50.a 51
Top guide vanes Pump shaft
64
Spacing pipe
64.a
Spacing pipe
64.c
Clamp, splined
Pa r t n o 85805906
Cl as s i f i c at i o n Dat a
Material type: EPDM Diameter: 16,3 Thickness: 2,4 Thickness: 3,3 Material type: EPDM Diameter: 137,5
Length: 8 Thread: M4 Dimension: 24/12 Designation: DIN 912 Thread: M8 Length: 25 Diameter: 5 Length: 26 Thread: RG 1/2 Thread: G 1/2 Length: 20 Thread: M8 Thread: M12 Thickness: 3,3 Material type: EPDM Diameter: 137,5 Thickness: 3,5 Outside diameter: 128 Outside diameter: 24 Inside diameter: 13 Designation: DIN 125 A Thickness: 2,5 Material type: EPDM Diameter: 16,3 Thickness: 2,4 Thread: M12 Length: 265 Length: 233,6 Outside diameter: 138
Bearing type: SILICON CARBIDE
Material type: SILICON CARBIDE
Inside diameter: 35 Height: 13,2 Outside diameter: 73 Diameter: 12,0 Length: 344,1 Outside diameter: 15 Inside diameter: 13 Length: 26,03 Length: 13 Inside diameter: 12,7 Outside diameter: 15 Outside diameter: 15,0 Inside diameter: 13,0 Height: 13,0
Qt y . 1 1 1 1 1
Un i t PC PC PC PC PC
1
PC
1 1 2 4
PC PC PC PC
1 4
PC PC
1
PC
2 1 1 4
PC PC PC PC
4 1
PC PC
1
PC
4
PC
2
PC
4
PC
1
PC
1 2 1 6 1 1 1 2 1 1 1 1 1 1 1 2 9
PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC PC
1 1
PC PC
6
PC
2
PC
1
PC
1/2