OPERATING MANUAL
M C
Document No. OPM/MC-New/002.04
BA/e 4330 Wä
Sulzer Pumps India Ltd. 1
9, MIDC, Thane-Belapur Road, Digha, Navi Mumbai, 400708. India. Tel. 091-22-55904321.Fax. 091-22-55904306
Content 1.
GENERAL REMARKS 1.1 About this manual 1.2 Guarantee 1.3 Type of operating manual 1.4 Service data - Service control
2.
SAFETY 2.1 Marking of instructions in the operating manual 2.2 Qualification and training of personnel 2.3 Danger on non-observation of the safety regulations 2.4 Safety-guided working 2.5 Safety instructions for user / operator 2.6 Safety instructions for maintenance, inspection and assembly jobs 2.7 Prohibition of unauthorized rebuilding measures or alterations 2.8 Inadmissible operating modes 2.9 Explosion protection
3.
TRANSPORT AND STORAGE 3.1 Transport / Lifting 3.2 Preservation and storage
4.
DESCRIPTION escription of the pump 4. Bearing bracket and lubrication 4. Absorption of the axial thrust - balance drum
5.
INSTALLATION 5.1 Mounting of the pump 5.2 Alignment of coupling 5.3 Suction and discharge pipework 5.4 Ancillary equipment 5.5 Minimum flow device
6.
OPERATION 6.1 General 6.2 Commissioning 6.3 Pump start-up and operation 6.4 Inadmissible operating modes 6.5 Shut-down 6.6 Restart procedure 6.7 Service control 6.8 Operating faults
7.
MAINTENANCE 7.1 Pump general 7.2 Shaft seal 7.3 Bearing / Lubrication
8.
OVERHAUL 8.1 Dismantling of the pump 8.2 Inspection of wearing parts 8.3 Assembly of the pump 8.4 Tools 8.5 Screw tightening torques
ENCLOSURES Table of enclosures for operating manual
4000/e0-1-00-000
2
1. GENERAL REMARKS 1.1 About this manual The operating manual contains important information on how to operate the pump safely, properly and most efficiently. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and life of the pump.
How to use this manual The operating manual must always be available wherever the pump is in use. These instructions must be read an applied by any person in charge of carrying out work with and on the pump, such as transport, storage, installation, operation and maintenance. This manual should be used together with all other machine documentation in order to have accurate information of your pump. Do not start or operate this pump unless you have complete understanding of the pump system and all auxiliary systems (driver, cooling, seal flushing ...).
1.2 Guarantee Guarantee is assumed according to the contractual agreements. The normal Sulzer warranty covers manufacturing or material defect, it does not cover the damage caused by improper storage conditions, incorrect installation, operation and using against designated use. During the period of guarantee, repairs or modifications only can be made by our service personnel or with our agreement.
1.3 Type of operating manual (Acc. to DIN 8418 and VDMA 24 292) Documents no.:
see cover sheet
Service address:
see cover sheet
Issue:
20
We reserve all rights in this manual and in the information contained. Reproduction, Reproduction, use or disclosure to third parties without our approval is strictly forbidden.
Revision history 3 2 1 0
20--25
First issue
E. T.
Revision
Date
Description
Sign
Remark In the case of further questions, of spare part orders and other correspondence please mention always the SULZER Serial No. and No. and pump type. Both can be gathered from the rating plate of the pump.
0000/e1-0-00-000
3
01
1.4 SERVICE DATA - SERVICE CONTROL
02
1.4.1 Data
03
Sulzer Serial-No.:
04
Position-No.:
05
Medium delivered
06
Capacity
m /h
07
Minimum capacity
m /h
08
Differential head
m FS
09
NPSH - R
m
10
Differential pressure
bar
11
Suction pressure norm./ max.
bar
12
Discharge pressure norm./ max.
bar
13
Pumping temperature (PT)
o
14
Specif. grav. at PT
kg/m
15
Pump input
kW
16
Speed
1/min.
17
1.4.2 Lubrication
18
Oil (according to DIN 51 524)
3 3
C 3
see also 7.3
19
Oil temperature
o
20
Quantity of oil per bearing frame
Liter
21
1.4.3 Cooling
22
Cooling water
m /h
23
Pressure normal/max.
bar
24
Temperature outlet max.
o
25
1.4.4 Heating
26
Heat exchanging medium
27
Pressure normal/max.
bar
28
Temperature entry max.
o
29
1.4.5 Flushing (shaft seal)
30
Flushing / Sealing medium
31
Quantity min.
m /h
32
Pressure
bar
33
Temperature of flushing medium
o
34
1.4.6 Flushing (wear ring)
35
Flushing / Sealing medium
36
Quantity min.
m /h
37
Pressure
bar
38
1.4.7 Quench
39
Quench medium
40
Quantity min.
m /h
41
Pressure
bar
42
1.4.8 Safety technical limit data
43
Max. allowable working pressure
bar
44
Max. allowable working temperature
o
C
3
C
C
3
C
3
3
C 4
0000/d1-4-02-000
R e f e r D o c u m e n t s a n d d r a w i n g s o f e a c h p u m p i t e m f o r d e t a i l s
2. SAFETY This operating manual contains basic information, which has to be observed on the installation, commissioning, operation and maintenance. Therefore this operating manual has to be available constantly on site for the use of service or site personnel and has to be read prior to commissioning and/or assembly/disassembly of the pump. Not only have the general safety instructions to be observed, which are given under this main point "Safety", but also the special safety instructions given below in the operating manual.
2.1 Marking of instructions in the operating manual The safety instructions contained in these operating instructions, which – if not observed - may result in harm to persons, are indicated with the general danger sign or, in the case of warnings against electrical voltage, with and in terms of explosion protection with the special sign For safety instructions which – if not observed – may cause risks for the machine and its operation, the word
ATTENTION
is inserted.
Indications which are directly attached at the machine itself such as - arrow for rotational sense - marking for fluid connections etc. have to be kept in good, legible condition, as they have always to be observed.
2.2 Qualification and training of personnel The personnel for service, maintenance, inspection and assembly has to hold the necessary qualifications for this kind of jobs. Range of responsibility, competence and the monitoring of the personnel have to be fixed clearly by the user. In case the personnel should not have the required knowledge, they have to be trained and instructed. This may be undertaken by the manufacturer of the machine, if required, on user's request. Further the user has to ensure that the personnel has a complete understanding of the contents of the manufacturer's instruction manual.
2.3 Danger on non-observation of the safety regulations By non-observation of the safety regulations danger may arise for persons as well as for environment and machinery and may lead to a complete loss of any claims for damages. -
Non-observance may lead for example to the following dangers:
-
Failure of important functions of machine/plant
-
Failure of required procedures of maintenance and repair
-
Endangering of people by electrical, mechanical and chemical impacts
-
Endangering of environment by leakage of dangerous materials
2.4 Safety-guided working The safety regulations given in this operating manual which consist of national regulations on accident prevention, as well as company- internal job, operating and safety regulations issued by the user, have to be observed.
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5
2.5 Safety instructions for user / operator -
In case hot or cold machine parts may lead to any danger, they have to be secured by user against touching.
-
Safety guards for rotating parts (e.g. coupling) may not be removed from machine during operation.
-
Leakages (e.g. from mechanical seal) of dangerous fluids (e.g. explosive, toxic, hot etc.) have to be disposed of in such a way as to prevent any endangering of people and environment. Legal regulations have to be observed.
-
Endangering by electricity has to be excluded (details see for example in the regulations by the VDE and local energy suppliers).
-
The special safety instructions in the following paragraphs of this operating manual have to be observed.
2.6 Safety instructions for maintenance, inspection and assembly jobs -
The user has to ensure that all maintenance, inspection and assembly jobs will be carried out by authorized and skilled personnel only, who have been adequately informed by studying the operating manual carefully.
-
Basically any works on the machine may be carried out only during shut-down of the machine. The procedure described in the operating manual for the shut-down of the machine has to be strictly adhered to. The machine has to be locked against unauthorized or involuntary start-up.
-
Employees with long hair must tie it back. No loose clothing or jewellery, including rings, should be worn. There is a risk of injury as a result, for example, of such objects getting caught or pulled in.
-
Pumps or aggregates delivering media hazardous to health have to be decontaminated.
-
Immediately following the end of the works, all safety and protective devices have to be reassembled respectively have to be put to work again.
-
On a repeated start-up all points given in the paragraph initial commissioning have to be observed again.
2.7 Prohibition of unauthorized rebuilding measures or alterations -
Alterations or rebuilding measures on the machine are only admitted in agreement with manufacturer. Original spare parts and auxiliary equipment authorized by manufacturer are meant to guarantee safety. The use of other parts may lead to a loss of the manufacturer's liability for the consequences.
2.8 Inadmissible operating modes -
The operational safety of the delivered machine is only guaranteed by proper use acc. to the data under item 1.4 of the operating manual.
-
The limits given in the data sheet must not be exceeded in any case.
2.9 Explosion Protection -
Any designation on the pump refers to that pump component only. Shaft coupling, driving motor (e.g. electric motor) and auxiliary systems (shaft sealing, lubricating oil system, etc.) must be looked at separately.
-
Improper operating methods that result in the specified temperatures being exceeded (exceeding or falling short of the operating data, falling short of the minimum delivery flow, reduction or failure of cooling water or circulation delivery, etc.) should be avoided at all costs.
-
Before starting the pump make sure that the pump system (suction pipe, pump casing and shaft seal) is completely full of delivery fluid. This prevents the existence of any potentially explosive atmosphere in the system.
-
Monitor pump operation constantly (instruments such as: manometers, thermometers, speed counters, ammeters, etc.).
-
Maintain the pump properly. Only machines that are in perfect technical condition can guarantee safe operation.
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6
3.
TRANSPORT AND STORAGE
3.1
Transport / Lifting
A. General remarks For all transport jobs the general rules of engineering and regulations on the prevention of accidents have to be strictly observed. These are especially VBG 1 - General regulations VBG 5 - Power-driven working devices VBG 8 - Lifting devices VBG 9 - Cranes VBG 9a - Load suspension device with hoists and conveyors The above regulations are applicable in the area of the Federal Republic of Germany, in other countries the appropriate regulations have to be observed. For the monitoring of a proper handling of lifting and transport jobs a competent instructor is to be named.
B. Transport Transport devices (including vehicles) have to be checked for the admissible load weight. Total weight of the delivered goods see dispatch documents. The load has to be secured during transport against shifting.
C. Lifting Check of the load suspension devices / ropes It has to be assured that admissible, undamaged ropes and lifting devices will be used. The loading capacity of the lifting devices and the ropes has to be suitable to take up the weight of the goods to be lifted. Load weight indications of the delivered units are given in the installation plan respectively the dispatch documents.
Sling rope as market on crate
Never stay within the range of suspended loads. Sketch 3.1-1
Fastening of the sling ropes on crates The points for the fastening of sling ropes on closed crates are marked. As the center of gravity (mass) cannot be recognized in closed crates, the sling rope fastening has always to be done at the marked spots. See sketch 3.1-1. Fastening of the sling ropes on bar shaft pumps The pump without packing can be lifted and transported by ropes witch are laid around casing parts (shaft seal housings). See sketch 3.1-2.
Sketch 3.1-2
Fastening spots for units In case lifting lugs or bars are attached at the baseplate, the unpacked unit has to be fastened at these spots by shackling the rope. See sketch 3.1-3.
If required use traverse
Sketch 3.1-3 Eyebolts at pump parts and other parts of the unit may not be used for the lifting of the complete assembled pump or even the whole unit. The eyebolts are only meant for the lifting of the loosened parts during assembly and disassembly
M000/e3-0-00-000 Page 1 7
3.2
Preservation and sto rage
A. General rem ark s This information will enable you to store your pump effectively and safely. Should further information be desired, or should particular problems arise which are not covered sufficiently please contact your nearest Sulzer representative. The following storage instructions apply only to the pump and may not be appropriate to furnished auxiliary equipment. Follow manufacturer’s instructions for all other components of the pump system. The preservation measures required for storage depend on the despatch preservation applied. The pump unit can be stored in a dry warehouse without maintenance measures up to the time given by the dispatch preservation.
B. Preservation for despatch Standard packing When the pumps are shipped, smooth outside faces are sprayed with “Tectyl 506” and pump internals with “Mobilarma 524” (or equal product). At tenti on: this is not suitable as long-term preservation; 6 months are max. allowed time for storing.
Seaworthy packing The pump is despatched with PE-foil welding and with added moisture absorber. Sea-worthy packed pumps can be stored up to one year without any special maintenance if the packing is not damaged.
Special packing On special request the pump can be packed in aluminium foil (with moisture absorber). In this case the preservation time amounts to 2 years without special maintenance. If the seaworthy or other special package is removed, only the standard preservation is ATTENTION effective, i.e. if no further measures are taken, the max. storage period will be 6 months.
C. Intermediate stor age Pumps which are not installed and commissioned immediately after delivery can be stored for the period determined by the dispatch preservation. ATTENTION To avoid the forming of condensate and consequently corrosion (especially in the gap areas), bearing damage and contamination, a dry room, possibly with constant temperature as well as a clean, shock- free storage space has to be selected. ATTENTION
In each case unfavourable climatic circumstances will have a negative influence on period of proper preservation.
In case the units are not or no longer enclosed in a special packing the following has to be observed: ATTENTION In case of unfavourable ambient impacts such as moist atmosphere, greatly varying temperatures (day/night), acidy or alkaline ambience, danger of contamination (dirt, sand, etc.) the connection flanges of the pumps have to be plugged airtight.
D. Longterm storage - preservation 1. General The pumps should always be stored in her functional position, that means that horizontal pumps should be stored horizontal and vertical pumps should be stored in vertical position. Align and support the pump as required. ATTENTION
In case of long term storage a number of precautions must be observed to prevent pump damage. It is recommended to enter all storage inspections and preservation measures in an log.
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Long term st orage may be required for: 1. New pum ps w itch are not commis sioned. The pump can be stored as described in Intermediate storage. After the dispatch preservation time measures have to be taken to protect the equipment against corrosion damage. 2. Stand by pumps or pumps affected by a longer shut dow n of the plant. The long term storage procedure depend on the material used in pump construction (cast iron, steel, stainless steel, special alloys), medium delivered and environmental conditions (freeze damage) see following table. Material of construction Cast iron Steel Stainless steel Special alloys
Medium delivered Neutral Hydrocarbon, ...
Water, ...
B B
A A
Aggressive Seawater, ... Acids, ...
B
B
A
B
B
A
A. The pump parts having been in contact with the pumped liquid must be flushed with neutral medium and after draining (and drying) be protected with a preservative. For this purpose the disassembly of the hydraulic part of the pump becomes necessary in most cases. Perform complete protection procedure described below in section 2. to 4. B. Let the pump filled with medium if there is no danger of freeze damage. Perform protection procedure for the bearing housing as described in the sections below. Warning: Rust preventatives can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturers.
2. Protection of not painted outer parts o f the pump - raised faces of flanges - pump shaft - coupling - connections for small conduits etc. We would urgently advise against using normal lubricating oil as a rust preventative. For the preservation of bright pump parts, the mineral-oil industry has developed special rust preventatives which at first are liquid and are applied manually, by means of brushes, spray nozzles or aerographs. After the evaporation of the solvent, a wax-type cover will remain. Pump outer parts: e.g.
This protective film can be removed by means of solvents or alkaline cleansing agents (see section V.). We recommend rust preventatives - Tectyl 506 from VALVOLINE - Rust Ban 397 from ESSO Other rust preventatives of the same quality may however be used as well. The average time of protection is 1-3 years. Rust preventatives are rust-preventing agents which however do not remove rust. For this reason, it is a prerequisite for the application of rust preventatives that the parts to be protected are clean and rustfree. The surface of the parts has to be cleaned carefully before the respective rust preventative is applied.
3. Protection of the interior of the pump If the hydraulic pump part (casing parts, impeller, wear rings…) are made of non-corrosive stainless or special alloy, no protective measures (instead of flushing, case A) are required. Note: Bearing housing and bearings have always to be protected. - pump casings Pump interior parts: e.g. - stuffing box chambers - bearing housing, bearings, ... 2 For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm /s should be used.
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We recommend the rust preventatives The rust preventative for the pump interior have to be selected according to the gasket or ATTENTION seal materials used. Gasket or seal material: Perbunan (NBR), Viton (FPM), Teflon (PTFE):
Rust preventativ e - Mobilarma 524 from MOBIL - MZ 110 from ESSO - Ensis motor oil 30 from SHELL
Ethylene-propylene (EPDM):
- Klüber Syntheso D 220
4. Proceeding in case of longterm preservation General Protect the pump and attachments with a vinyl-coated nylon tarpaulin. Lash tarp evenly to provide drainage that does not form pools. Maintain sufficient air circulation with minimum 10 cm clearance between tarp and pump parts. Protect pump from blowing s and or dirt. Shaft seal Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. The use of any preventative is not recommended. Soft packing If the pump is supplied with a stuffing box packing installed, the packing has to be removed and replaced by a special packing which is to remain in the stuffing box chamber during the preservation time, only. ATTENTION
Preservation packing material recommended: Synth. fibres, with PTFE impregnation (e.g. Chetra 1711 GS or Hecker 1820). The packing chamber is filled completely with the separate packing rings. Pump casing At first the raised faces of the pump flanges have to be cleaned thoroughly and preserved with one of the rust preventatives mentioned under I. On smooth flanges and those with annular tee-slots, flat gaskets should be placed; in case of slotted flanges, 2 gaskets should be placed in the slot, and all the sockets have to be closed tightly by means of metal covers. The connections for the cooling water/circulation lines etc. should also be closed by means of normal steel plugs, using Molykote. Then fill (or spray) pump casing with rust preventative (see 3.). While filling in this agent, turn pump shaft manually several times (observe sense of rotation). Generally speaking in practical handling the casing interior of bigger pumps usually is only sprayed, in this case the preservation has to be repeated every 6 months. Bearing housi ng If present: Drain lubrication oil thoroughly. Remove filler plug on the top of bearing housing and fill bearing housing with rust preventative (see II.) up to the correct oil level. During filling rotate the pump shaft by hand in the proper direction. If present: Fill also constant level oiler bottle with rust preventative.
E. Maint enance of the long term stored pumps Visual ins pection The exterior of the stored pump unit should be conducted every 30 days and inspected for surface damage, dirt or animals in the pump area. If required initialise appropriate measures.
Maintain rust prevention coatings If any rust is observed, measures should be taken to remove rust and protect against it.
Turn pump rotor manually To avoid corrosion damage at bearings, drain the preservation oil every 3 month and refill if on the top of the bearing housing. The pump rotor should manually be turned simultaneously, so that the preservation oil will be distributed over the running surfaces of the bearings. Turn pump rotor at least 5 revolutions in the proper direction of rotation.
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Filled pump parts At the parts which are filled with rust preventative (pump casing / bearing housing) the condensate should be drained every 6 months; rust preventative should be added, if required. According to manufacturers indications, the rust preventative has to be drained and refilled every 12 month. If the rust preventative is not renewed within this period the risk is to be taken by the storage keeper. In order to have a guarantee for the proper execution of the maintenance instructions, we recommend to establish maintenance sheets. ATTENTION
If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than after 6 months.
F. De-preservation procedure Surface protected parts In most cases the protection film must not be removed. If required remove rust preventative by the following cleaning agents: benzine (gasoline), alcohol, petroleum, acetone. Alkaline cleaners can also be used. Warning: Cleaning agents are highly flammable and can cause skin irritation. Follow all safety precautions specified by the manufacturers. Note: Do not use nitro thinners!
Pump casing Drain pump casing thoroughly, it may be required to lift the pump to fully drain the pump casing (see job specific drawings). If required flush pump casing, turn pump rotor by hand in the proper direction of rotation. For absolutely cleaning (pumping of clean product) the disassembly of the hydraulic part of the pump becomes necessary in most cases.
Shaft seal Mechanical seal: The complete mechanical seals remain within the stuffing box chamber. Elastomer seals are subject to material specific and time-based alteration (aging) witch might reduce the efficiency of the seal, therefore we recommend after a storage time for more than 3 years to change the seal rings. Packing: Before commissioning, make sure that the preservation packing is removed and replaced by packing rings of the quality provided for operation.
Bearing hous ing Put a tray under oil drain to catch the whole quantity of oil securely. Remove screw plug and drain the preservation oil thoroughly. Flush bearing housing with lubrication oil and allow to drain. Mount constant level oiler (if removed) and refill bearing housing with lubricating oil as given in the pump operating manual. Dispose of rust preventive oil according to statutory regulations. Do not put into waste water by any means.
G. Additi onal Information When the pump is removed from storage special care have to be taken. Clean pump and equipment surfaces (piping, coupling, driver,…) and inspect:
Minimum checks
Additi onal recommended checks
Inspect for completeness Check all pressure case (plugged) openings and connections for tightness Check for any sign of cracks or damage Check pump rotation, check for correct gap between stationary and rotating parts
Check coupling alignment
Check all fasteners for tightness
Inspect bearings (if any sign of contamination be detected, replace brg.) Inspect shaft seal and change all elastomer seal rings Install additionally suction strainer …
Check service data (are the pump suitable) If the pump has been stored for more than 3 years we recommend to open and inspect at ATTENTION least bearings and shaft seal before start-up. If the pump has been stored for more than 5 years we recommend to disassemble the pump and change all gaskets and seal rings.
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4. DESCRIPTION 4.1 Description of the pump
General: Pumps of the MC series are horizontal, multi-stage, ring section centrifugal pumps designed for boiler feed and other high pressure applications. The pumps are suitable for pumping clean liquids. The permissible operating pressures and permissible operating temperatures depend upon the material specification. See 1.4.8 for safety limit data for the pump supplied. ATTENTION
The materials of construction have been selected for the liquid specified in your order. Before the pump is operated with other liquids or at other temperatures it is essential that the manufacturer be consulted. ATTENTION
Casing: The casing is radially split and consists of suction casing, stage casings as required and discharge casing. The elements are sealed by O-rings and held together by external tie bolts. Shaft: Accurate machining provides precision fits and clearances for assembly and operation. Machined shoulders provide positive location of mounted parts. Impellers: The impellers are key-driven, have closed channels and are sealed against the casing elements by replaceable casing wear rings. The flow is guided from stage to stage by stationary diffusers. Shaft seal: The inner chamber of the pump which is filled with liquid is sealed at the shaft by packed glands or mechanical seals. See 7.2 or description of the seal manufacturer for further information. The shaft seal housings are fitted with a cooling chamber as required. In order to prevent evaporation in the vicinity of the shaft seal, the cooling water quantity given under 1.4.3 must be assured. Non-compliance can lead to total failure of the shaft seal. ATTENTION
Coupling: Flexible couplings must be used to connect the pump to the driver: these couplings must be able to absorb small axial, radial and angular shaft misalignments.
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4.2 Bearing and lubrication Bearing housin gs: The bearing housings flanged on both pump sides are equipped with ring oil lubricated bearings. The lube oil quantity is given under 1.4.2 and 7.3. ATTENTION
Depending on the service conditions the bearing housings may require water cooling to maintain acceptable bearing temperature. In this case the cooling water quantity is given
under 1.4.3. Anti fr ic ti on bearings : Roller bearings are used as bearings for the massive pump shaft in the bearing bracket on the drive side, whereas paired taper roller bearings take up the axial forces at the non-drive side. Fan: A fan assembly is provided to enhance air cooling of the bearing bracket non-drive side. Constant Level Oiler: An oiler is installed on each bearing housing. The oiler automatically maintains bearing housing oil level and provides a means of monitoring and refill. See also 7.3 Sight glass: A sight glass is provided to allow visual monitoring of bearing housing oil level. Lube oil system: Both bearing housings are provided with rotation-independent lube oil systems. The oil ring rotates with the shaft and continuously distributes lube oil from the bearing housing sump into the bearing cover whence it circulates through the antifriction bearings back into the oil sump. The lube oil quantity is given under 1.4.2 and 7.3 .
Bearing bracket non-dr ive side tapered roller bearing (or angular ball bearings)
vent plug (oil fill connection) roller bearing
fan
shaft oil drain plug
4330/e4-1-01-000 Page 2
Bearing bracket dri ve side
13
4.3 Absorpti on of the Axial Thrust - Balance drum General During operation of the pump an axial thrust is exerted on the rotor towards the suction side. This arises because the area of the back shroud of the impeller is larger than that of the front shroud which is interrupted by the impeller eye, both being subjected to the same liquid pressure. In multi-stage pumps the forces per stage are cumulative and considerable axial loads result. These forces are absorbed by the hydraulic balance device.
Working principle The balance device consists of a balance drum rotating with the shaft and a balance drum liner housed in the discharge casing. The pressure difference between the pressure within the pump 'a' (discharge pressure) and the pressure in the balance chamber 'b' (suction pressure + frictional resistance in the balance pipe) creates an axial force 'F' on the balance drum. This axial force is opposite in direction to the pump axial thrust. The magnitude of the force 'F' depends on the area " A" of the balance drum which is sized such that the axial thrust at the operating point is almost completely compensated. The residual axial thrust is absorbed by a thrust bearing. The pressure difference between 'a' and 'b' also sets up a flow through the throttling clearance 'c' into the balance chamber. A perfect balance is only achieved if there is no build up of pressure in the balance chamber as a result of the balance flow being restricted.
605.01
a
b 603.01
axial thrust
Balance pipe ATTENTION
Severe damage to the pump will result, if the instructions for the laying of the balance pipe are not strictly observed.
To prevent a pressure build-up in the balance chamber there must be a drain for the admitted liquid. A tapping for this purpose is provided in the pump balance chamber (the position is indicated on the dimension drawing). ATTENTION
- The routing of the balance pipe depends on the operating conditions. It is either: returned to the suction tank or returned to the suction casing. The data on the installation drawing is decisive for the pump supplied. Note! With flow returning into th e suction tank the follow ing must be observed: ATTENTION
The frictional resistence of the balance pipe must not exceed 0,8 bar. Choose corresponding nominal diameter.
A valve should be fitted in this pipe for maintenance purposes. Steps must be taken to ensure that this can be locked in the open position to prevent unauthorized and/or accidental closure. ATTENTION
Damages on the balancing device may lead to a heating of the balancing liquid causing inadmissible pressure in the balancing tube. A security valve has therefore to be built into this tube. Adjust opening press ure at 5 bar over inl et pressu re.
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5. INSTALLA TION 5.1 Installation of t he pump u nit A. Gen eral (refer to Job specific drawing(s), Installation plan …) Machinery intended for use in potentially explosive areas must satisfy the “Ex” protection requirements. Check the documentation relating to the machinery and accessories (and nameplates). Good planning and preparation result in fast, simple and correct installation. Safe running conditions with maximum accessibility are assured. When preparing for installation of the machine, it is necessary to take the following aspects into account: The main dimensions, connections, position of fixing bolts etc., are shown on the dimension drawing/installation plan. Suitable lifting devices must be available for installation and repair work. Good lighting is important and sockets for portable lights should be available. The pump should be readily accessible from all sides. The pump foundations and type of installation should be designed so that vibration is kept to a minimum both during operating and when the pump is at rest, otherwise the pump life will be reduced. A drain must be provided so that gland leakage, cooling water (open system) and liquid drained from the pump during overhaul can be led away. The draining of the pump respectively the disposal of the leakage for pumps delivering toxic, explosive, hot or in any other ways dangerous fluids, must not lead to any endangering of operator(s) and environment. Following manufacture the pump flanges and external tappings are protected by metal closures at least 5mm thick, with elastomer gaskets, which should not be removed before the pipework is ready to be attached to the pump. The pump should be protected, if further site work is necessary nearby. The foundation or any other necessary building work must be finished, set and dried. Roughen and clean the foundation. All preliminary work for erection must be completed. With large units, suitable door and wall openings are to be provided for transport to the installation site. Grout selection Select a non-shrinking grout that is compatible with the highest and lowest temperatures to which it may 2 be exposed. Use concrete from a concrete company with a final strength of 25 N/mm (B25) or better. If the service of a concrete company is not available the figures given below may be taken as a guide. - The concrete mixture suitable for grouting machine baseplate should contain 300 to 350 kg cement per 3 3 1 m (20 to 22 pound per cu. ft.) of concrete. The sand and gravel proportion for 1 m (1 cu. ft.) of 3 finished concrete (1.2 m (1.2 cu. ft.) mixture) is as follows: For grouting
65% Fine sand
grain size
1 - 5 mm
(0.04 – 0.2 in.)
of the foundation bolts
35% Coarse sand
grain size
5 - 10 mm
(0.2 – 0.4 in.)
water as required The use of so called „fast cement“ with short setting time is possible. For grouting (filling)
40% Fine sand
grain size
1 - 5 mm
(0.04 – 0.2 in.)
of the baseplate
60% Coarse sand
grain size
5 - 15 mm
(0.2 – 0.6 in.)
100 - 140 liters (7 - 10 gallons) of water Table 5.1.1 ATTENTION Only clean, washed sand may be used. The water-cement ratio has a decisive influence on the final strength of the concrete. A high concrete strength will be attained with high standard strength of the cement, low water-cement ratio, and compacting by vibrating.
4330/e5-1-00-001 page 1 15
Tools and Equipment Required The following tools will be required temporarily for the installation work: -
2 Dial gauges
-
1 Spirit (machinist’s) level
-
1 Set of standard hand tools
-
Suitable lifting devices for installation and repair work.
-
Suitable lighting
B. Mechanical completion and installation sequence check list REF. PAR.
EVENT
5.1 A-G
Instructions for site installation
5.1 C
Installation of pump and driver
5.1 D
Levelling, check leveling of baseplate
5.1 E
Grout in foundation bolts
5.1 G / 5.1 D 5.2 A-H
Let the concret set Snug-Up (tighten) foundation bolts and recheck levelling Mount driver (If field mounted) Align driver to pump
5.2 D
Check for soft feet, pump and driver
5.1 F
Grout baseplate
5.1 G
Final tighten of foundation bolts after grout cures
5.3 A-H
Install main piping
5.3. C
Check stress free pipe connection
5.3 F
Clean the pipework
5.4 A-H / 8. A-B 5.5 A-B 5.2 A-I
Mount ancillary equipment Install Minimum flow device (if present) Fill and vent the pump system Final alignment (mount coupling guard)
Table 5.1.2 Check off when satisfactorily completed
C. Installation of pum p and driv er Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. Note: With separate baseplates for pump and driver first erect the pump, then align the driver. Precondition - The location place must be sufficiently rigid to prevent pump vibration. The specific base design will depend on location and external piping forces requirements. Location pl ace / surface check - Check mounting surfaces. All location place surfaces used for mounting the pump unit must be clean. Remove rust, dirt or other extraneous material. - Roughen and clean the foundation. Walls of the grouting holes must have rough surfaces and must be free from pollution. Remove any loose particles, dirt or oil-soaked concrete. All baseplate surfaces which will be in contact with grout must be clean. Remove rust, paint or other extraneous material.
4330/e5-1-00-001 page 2 16
Installation - Attach wire rope slings to the pump unit (see 3. Transport and lifting) and lift the pump unit carefully. Insert foundation bolts into the holes in the baseplate and tighten the nuts a few turns. - Lower the baseplate carefully into position on the fo undation. The foundation bolts have to be lowered into the foundation holes.
D. Levelling Use mechanical installation report TC 0000/5-1-00-000. - Place steel shims under the adjusting screws and align the pump unit horizontally with the aid of the adjusting screws. Provide proper grouting clearance between foundation and baseplate (see installation plan). ATTENTION Check levelling in the direction of the pump axis and also at right angles along the horizontal flange with a spirit (machinist’s) level. The flanges must be vertical on horizontal branches. See sketch 5.1.1. Preferred variance : 0.2 mm over 1 m (0.003 in./ft .). Maxim um allow able variance: 0.5 mm ov er 1m (0.006 in./f t.). - Push steel shims into line to the right and left of the foundation bolts. The shims must be thick enough so that there will be only minimal clearance between baseplate and shim. The space between baseplate and shim must be filled with one or two thin parallel sheet metals which must be available in different thickness. See sketch 5.1-2. - Loosen adjusting screws and check levelling. If required correct levelling.
spirit level pump flange
adjusting screw
foundation bolt disc
baseplate sheet metal
shim
shim
concrete shaft
Sketch 5.1-1 Levelling the unit
foundation
Sketch 5.1-2 Grouting foundation bolts
E. Grout in the foundation bolts - Before grouting wet the foundation holes. Fill foundation holes with concrete. See sketch 5.1-2. - After setting tighten the foundation bolts (see table 5.1.3) and check ho rizontal alignment again. If the position of the pump has changed, correct alignment. ATTENTION
Do not bend the baseplate since this will cause development of vibration and noise during operation or the alignment of the coupling will not possible.
- Before grouting the baseplate align the coupling as described under 5.2 (alignment report).
4330/e5-1-00-001 page 3 17
F. Completion of grout ing (when properly aligned) Grouting of the machine into the foundation is a very important part of the installation. Problems can arise, if materials are of poor quality, which may show up early or after several months of operation. ATTENTION
-
-
Build a dam around the foundation. Forms must be strong enough to withstand the grout pressure. Attach a chamfer strip on the form inside, at grout grade elevation, to provide a neat beveled edge. See sketch 5.1-3.
grout hole
baseplate
chamfer strip
Finish grouting the baseplate in conformity with the corresponding installation plan. Fill the baseplate with thinbodied concrete through grout holes. Take care that the baseplate is completely filled with grout, vibrate as necessary.
The concrete must neither dry out nor freeze during the first 48 hours. During this time the o temperature of the foundation should not fall below 10 C o (50 F). The optimum temperature for the setting process is o o o 20 C +/-10 C (65 +/-15 F).
grout
ATTENTION
-
foundation
5.1-3 Grouting of baseplate
If necessary: Seal the grout openings by covering with a quality paint or with grout hole covers.
When the concrete has set, re-tighten foundation bolts (see table 5.1.3) and check coupling alignment (alignment report).
G. Tightening to rques for foun dation bolts Thread size (OD in.) Tightening torque Nm (lbf.ft)
M 12 (0.40)
M 16 (0.60)
M 20 (0.80)
before grouting of baseplate
15 (10)
30 (20)
70 (55)
140 (105) 280 (210)
FINAL after grouting of baseplate
20 (15)
50 (40)
100 (75)
180 (135) 350 (260)
Table 5.1.3
4330/e5-1-00-001 page 4 18
M 24 (0.95)
M 30 (1.18)
Title:
Test Certi fic ate
Mechanical Installation
Plant / Location:......................................................................................................................................... Aggregate Specification:............................................................. .............................................................. Pump type:......................................................
Driver:..............................................................
Serial-No.:.......................................................
Type / No.:.......................................................
Measures
Confirmations
1. Foundation construction Main dimensions and connections checked 2. Level baseplate
Yes
No
Date:
Sign:
Date:
Sign:
longitudial
crosswise
Levelling Direction
longitudial
crosswise
Measured:
.................
................
Prescribed:
X
Check distance between baseplate and foundation
0 ... 0.5 mm over 1 meter
Dimension X
Min:
Max:
Foundation bolts grouted
Yes
No
Date:
Sign:
Foundation bolts tightened after setting
Yes
No
Date:
Sign:
3. Foundation bolts
4. Grouting baseplate Levelling checked Baseplate completely filled with grout
Direction
longitudial
crosswise
Measured:
.................
................
Yes
No
Date:
Sign:
Coupling alignment checked
Yes
No
Date:
Sign:
Pump foot and driver tightened
Yes
No
Date:
Sign:
Stress control of main piping performed
Yes
No
Date:
Sign:
Piping cleaned and connected (main and auxiliary)
Yes
No
Date:
Sign:
Electrical connections (main and auxiliary)
Yes
No
Date:
Sign:
Lubrication check (pump, driver, ...)
Yes
No
Date:
Sign:
Driver test run, rotation check (pump uncoupled)
Yes
No
Date:
Sign:
5. Piping connection
6. Auxili ary checks and connections
7. Syst em chec ks
TEST DECLARATION
System cleaned
Yes
No
Rework:
System filled and vented
Yes
No
Yes
Pressure tested
Yes
No
Accepted: No
Yes
No
TC 0000 / 5-1-00-000
Date:
Sign:
4330/e5-1-00-001 page 5 19
Page … o f …
5.2. Alignment of coupling A. Gen eral If the Sulzer scope of supply does not include the coupling / coupling protection, ensure that only approved materials and designs are used for applications in potentially explosive areas. Driver “ No Load” run Before final aligning the coupling, and with the pump and driver uncoupled, check the direction of rotation of the driver corresponding with the direction of rotation arrow on the pump. The assembly of auxiliary equipment, and the electrical hook-up in the case of an electric motor, must be completed in accordance with the manufacturer’s requirements. Refer to the driver manufacturer’s manual for details. "No-Load" driver testing will allow the driver rotation to be checked and provide an opportunity to make final equipment adjustments before coupling to the pump. Flexible couplings need very careful alignment of the shafts which can be achieved by placing thin shims under the machine feet. Negligence in alignment will destroy the coupling and damage the pump and motor bearings, too.
ATTENTION
ATTENTION
When applicable, ensure that any rotor locking devices are removed before attempting to turn rotors.
ATTENTION
Bearings must be lubricated BEFORE attempting to turn rotors. Avoid any unnecessary turning of machine rotors.
ATTENTION
Whenever practical, the pump must be filled with product before turning by hand.
ATTENTION
Stainless steel fitted pumps are particularly susceptible to “pick-up” and turning by hand should be avoided whenever possible.
Scope This section describes recommended procedures for aligning the motor (driving machine) to the pump (driven machine) for the pumpset supplied. 1. Determine which machine is to be levelled and positioned correctly and then used as the reference machine (normal pump). The position of this machine will then remain fixed, and the adjacent machine(s) will be moved as necessary to align with it. See sketch 5.2-1. 2. Ensure that the reference machine (pump) is level and positioned correctly. 3. Work outwards from the reference machine, and position the next machine A in the train with the correct gap between coupling flange faces or shaft ends (as applicable) and align the shaft to the shaft of the reference machine. 4. Where a further machine B is included in the drive train, use machine A as the reference machine to position and align B to A. In the same way, position and align C to B, etc.
B
A
Reference Machine
A
B
D
C
B
A
Reference Machine
Sketch 5.2-1 Reference machine – next machine
4330/e5-1-00-001 page 6 20
B. Misalignment types There are three basic types of misalignments between the pump and driver shafts:
Sketch 5.2-2 Angular mi salignment Shafts with axes that intersect at a point
Sketch 5.2-3 Parallel offset Shaft with axes parallel but offset
Sketch 5.2-4 Ax ial di st ance Shaft with axes parallel but wrong distance
C. Assembly The assembly of the coupling must be carried out in accordance with the coupling manufacturer's instructions. For mounting the coupling halves onto shaft ends see also maintenance manual.
D. Check for „ soft machine feets” Before coupling alignment the driver and pump fixation must be checked regarding “soft feet“ issue. Loosen machine feet fasteners one after the other and check with feeler gauge if a gap between machine feet and baseplate occur. If the gap is larger than 0.05 mm (0.002 in.), then the gap have to be compensated by shimming. If the base plate has not grouted yet, the “soft feet” may also be compensated by re-adjustment of the baseplate. If the pump or driver are not properly fixed to the base plate higher intermittent vibrations or excessive misalignment due to nozzle loads can be expected .
E. Pump foot tightening torques For the transport the tie bolts have to be tightened at the pump feet. To render possible a tension-free thermal expansion of the pump during operation, the screws loosened again for the precision alignment of the coupling must not be screwed so tight on the non-drive side as on the drive side. Essential values for the tightening torque of tie bolts on drive side and non-drive side are shown in the table below. Thread size nominal diameter mm in.
Tightening torque Drive side Non-drive side Nm lbf.ft Nm lbf.ft
M 16 (0.6) M 20 (0.8) M 24 (0.95) M 27 (1.05) M 30 (1.18) M 33 (1.30) M 36 (1.42) M 42 (1.66) M 48 (1.88) M 56 (2.20) M 64 (2.51) Table 5.2.1
60 120 220 350 480 680 900 1500 2400 3900 5900
44 88 160 255 350 490 650 1080 1740 2820 4270
40 80 140 220 320 450 600 1000 1600 2600 3900
30 60 100 160 230 325 435 725 1160 1900 2800
4330/e5-1-00-001 page 7 21
Non- drive end
Tightening torque acc. to table
Drive end
Tightening torque acc. to table
Sketch 5.2-5 Pump foot tightening torques
F. Compensation of t hermal gr owth Temperatures have a considerable influence and should therefore be considered during the alignment. The shaft centreline of each pump and driver will rise when they reach operating temperature. Therefore, the difference between the two anticipated growths should be incorporated into the cold alignment so that the shafts will come into alignment when operating temperature is attained. The unit with the greater thermal growth must be set lower than the other unit, by the difference between their thermal growth. Pump thermal grow th At pumps with feet bottom (not at axe level) and ATTENTION o operating temperatures above 80 C the thermal growth should be considered according following table. Pump size MC 40 – 180 50 – 220 80 – 260 100 – 300 150 – 360 200 – 400
H
160 185 240 275 325 360
> 80 0.10 0.11 0.14 0.17 0.20 0.22
Thermal growth H in mm o with operating temperature C > 100 > 130 > 150 > 170 0.13 0.18 0.22 0.25 0.15 0.21 0.25 0.29 0.20 0.28 X X 0.23 0.32 X X 0.27 X X X 0.30 X X X
X = Casing feet at axe level
Shaft
Thermal growth
H
Shaft
Thermal growth X negligible
Sketch 5.2-6 Pump thermal growth
Driver thermal grow th
The thermal growth of the driver equipment must be obtained from manufacturer instructions. Thermal growth varies with temperature, load and ambient conditions. With drive equipment by gear or steam turbine an additional lateral and/or axial thermal growth have to be considered.
ATTENTION
G. Axial shaft d ist ance The axial distance between the coupling halves must be observed. Please see installation drawing and hints on coupling assembly. Refer also to manufacturer’s instruction. The shaft of a driver without a thrust bearing must be set in proper running position before distance between shafts is adjusted. Refer to driver manufacturer instructions. Coupling Hub Spacing
DBCFF or DBFF
Note: Where coupling f lange faces do not align with shaft ends, (see sketch 5.2-7) distance between coupling flange faces (DBCFF or DBFF) is normally specified on the appropriate drawings, and should be used as the reference dimension for setting correct spacing between machines. The distance between shaft ends (DBSE) may also be shown but is not to be used as a reference dimension. Where coupling f lange faces do align wi th sh aft ends, distance between coupling flange faces, DBSE is normally specified on the appropriate drawings, and should be used as the reference dimension for setting correct spacing between machines.
4330/e5-1-00-001 page 8 22
DBSE
Sketch 5.2-7 Coupling hub spacing
H. Alignment General Any change in elevation can be accomplished by shimming between equipment feets and baseplate pedestals. The maximum number of shims is four. After alignment tighten pump foot fasteners according to the given torques (see pump foot tightening torques) and re-check alignment. The coupling alignment certificate TC 0000 / 5-2-00-000 have to filled in during each alignment check / procedure (see next pages). Each alignment check / control has to be done only with pump in cold condition and under consider of the thermal growth of pump and driver. Hot alignment procedure after stop from hot service are not allowed.
ATTENTION
Alignment of coupling must also be monitored during pipework connection and re-checked after pipework connection to ensure that pipework connection does not adversely affect alignment. If alignment is affected, the pipe connections must be re-made until alignment remains correct. ATTENTION
Do not adjust driver OR driven machine positions to correct alignment errors caused by pipe connection.
Adju st ment d evice For axial and lateral moving of heavy equipment (motor) a device has normally been fitted at the baseplate machine fastening pedestals. See sketch 5.2-8. Loosen equipment fastening screws and move the machine by tightening the adjusting screw into appropriate direction. Note: Before moving the machine be sure oposite adjusting screw are loosened. ATTENTION
After alignment and tightening the machine fasteners loosen all adjustment screws. Adjustment devices
Ad ustment screws
Machine feet
Baseplate pedestals
Moving machine
Baseplate pedestal
View "X"
Sketch 5.2-8 Adjustment device
X
Coupling alignment pr ocedure Every alignment check must be preceded by a run-out measurement. Record the results always in the coupling alignment Test Certificate. Vertical alignment is checked first, and any required adjustment is applied. Then, the horizon tal alignment is checked and any required adjustment is applied. Loosen the hold-down bolts on the moveable machine, lift the machine and insert sufficient shims under the mounting feet to approximately align the shaft with the shaft of the reference machine, taking into account the cold-offset (thermal growth). Slotted shims of at least the same size as the mounting foot must be used. The shim stock should ideally be stainless steel and be available in various thicknesses. For horizontal alignment in most case positioning jack screws are provided. Tighten or loosen jack screws as required to align the shaft with the shaft of the reference machine. After shimming and horizontal aligning tighten down the reference and moveable machine hold-down bolts to the correct torque value and recheck alignment. If required correct alignment.
4330/e5-1-00-001 page 9 23
Tolerances The maximum admissible axial misalignment is 0.05 mm (0.002 in.) on diameter, although ≤0 .03 mm (0.0012 in.) is preferrable. The maximum admissible radial misalignment is 0.1 mm (0.004 in.) on diameter, although ≤0 .05 mm (0.002 in.) is preferrable. Clock gauge alignment Alignment should be carried out with clock gauges in radial and axial direction (see sketch 5.2-9). Ensure that the supports for each indicator are sufficiently rigid to eliminate any sag that may cause spurious readings. All readings for radial and axial misalignment are determined in the gauge positions: top, bottom, right and o left, i.e. every 90 , while both shafts are simultaneously turned. Optical Alignment Instead of using a clock gauge assembly, optical (laser) alignment equipment may be used. Laser optical alignment is the most exact shaft aligning method. The transmitter is a laser diode mounted on one side of the coupling and the prism is mounted on the other side. The laser beam emitted by the laser diode is reflected by the prism to the localizer. The offset can be detected by rotating the shafts.
Sketch 5.2-9 Alignment of spacer couplings
Sketch 5.2-10 Optical Alignment
I. Coupling safety guard The pump must only be operated with mounted coupling safety guard. After each alignment check the coupling guard must be refitted immediately. Check for correct assembly, fastening and distance to rotating coupling.
4330/e5-1-00-001 page 10 24
Test Certi fic ate
Title:
Coupling alignment
Plant / Location:......................................................................................................................................... Aggregate Specification:............................................................. .............................................................. Pump type:..............................................................
Driver:..............................................................
Serial-No.:...............................................................
Type / No.:.......................................................
Alignment before pipework connection:
Remark:..............................................
Alignment after pipework connection:
...........................................................
Alignment before commissioning:
...........................................................
Alignment after commissioning (maintenance):
...........................................................
1. Axial distance check Coupling gap (mm) Specified gap: Pump
Driver Spacer coupl.
Pump
Tolerance:
Driver
Actual gap:
Non-spacer coupl.
Coupling type:....................................................
Spacer: ...............mm Yes
No
2. Check of radial mis alignm ent (see also 2.1) Radial misalignment (mm) Measuring p.
Left
Right
Top
Bottom
Measured: Pump
Prescribed:
Driver
0 ... 0.1 (0.05 preferable)
2.1. Check of correct axis disp lacement (only in case of defined displacement by different thermal growth between driver and driven machine) Ax is di splac ement (mm) Displacement
Horizontal
Vertical
Measured: Pump
Prescribed:
Driver
0 ... 0.05
Driver is set ............... mm higher / lower Driver is set ............... mm t o right / left 3. Check of axial misalign ment (parallelism) Ax ial mi salignment (mm) Measuring p.
Left
Right
Top
Bottom
Measured: Pump
Driver
Prescribed:
0 ... 0.05 (0.03 preferable)
4. Bolt tightening check (after alignment)
Test declaration
Pump foot checked:
Yes
No
Rework:
Driver foot checked:
Yes
No
Yes
Anchor bolt checked:
Yes
No
Accepted: No
Yes
No
TC 0000 / 5-2-00-000
Date:
Sign:
4330/e5-1-00-001 page 11 25
Page … of …
5.3. Suction and di scharge pipewor k A. Gen eral Welding, burning and grinding work should only be carried out on the pump where specifically authorised, e.g. there may be a risk of fire and explosion. Pipe diameters will have already been determined at the planning stage and many factors unknown to the pump manufacturer will have been taken into account. As a general rule the liquid velocity should not exceed 2 m/sec (6.5 ft./sec) in the suction pipework and 3 m/sec (10 ft. sec) in the discharge pipework. It is also good engineering practice to increase the size of both suction and discharge pipes at the pump nozzles in order to decrease the head loss from friction. For the same reason piping should be arranged with as few bends as possible and even then should be made with a long radius wherever possible. A few useful hints are given below which should be observed when the pipework is installed. In case the possibility of dangerous recirculation may occur after shut-down of pump, ATTENTION especially with "emergency trip out", back-flow preventors (check valve) have to built in.
B. Assembly The pipework must be supported in an adequate manner to ensure that no inadmissible bending moments or stresses caused by the weight of the pipework or thermal expansion are transmitted to the pump flanges (install an expansion piece). All supports and expansion equipment must be installed before making connections to pump flanges. Ensure that the correct gasket is used at all flanged joints and that the gasket is mounted concentric with the bore of the pipe. ATTENTION
C. Stress free pipe connectio n The stress free pipe connection is to be checked (cold condition, pump empty) in the following way: The pipe has to be suspended over the pump flange and there must be space enough to easily build in the sealing. The supports have to be designed in such a way that the weights of the pipe and the fluid are compensated and will not put inadmissible high pressure on the pump branch (observe nozzle loads in the installation plan). Higher than the given max. admissible nozzle loads may lead to a sudden leakage of medium delivered, life danger occurs. If the pipe supports (especially fixed points) are not near to the pump with 1 or 2 elbow ( 45 or 90° direction change ) the pipe can be considered as flexible. In such cases following tolerances can be used for “stress free connections” : •
•
•
A
Pipe
Pipe
S
Pump case
Pump case
Sketch 5.3-1 Radial misalignment
Sketc h 5.3-2 Angular displacement
4330/e5-1-00-001 page 12 26
Stress free connection for f lexible suction and disc harge pipes (cold conditio n) Pipe nomi nal diameter
up to 200 (8 in.)
Radial misalignment
A
Angular displacement
S
over 200 (8 in.)
max. 0.5 mm (0.02 in.) max. 0.2 mm (0.008 in)
max. 0.4 mm (0.016 in.)
If the pipe is considered as not flexible, so 50 % of the tolerances of flexible piping can de used. Be sure the max. admissible nozzle loads ( see installation plan) are not exceeded. Adjustments must be made to the piping, if these limits are exceeded or serious damage ATTENTION to the pump may result. •
D. Pipe fitt ings Discharge line A check valve and a shut-off valve should be installed in the discharge line. The check valve, placed between the pump and the shut-off valve, is to protect the pump from reverse flow and excessive back pressure. The shut-off valve is used in priming, starting and when shutting down the pump. Suction line In the suction line a shut-off valve should be installed for extended shut downs, repairs and for pump dr aining. It must be fully open during operation, and must not be used for pump regulating. Fittings having the same nominal bore of the pipework should be used. If the pump ATTENTION branches have a smaller nominal bore than the fittings suitable taper pieces should be installed.
E. Suction pipe On flooded suction applications, the horizontal sections of the pipework should descend towards the pump and on suction lift applications they should steadily rise towards the pump to prevent air locking.
Sketch 5.3-3 Flooded suction (Suction head)
Sketch 5.3-4 Suction lift
The pieces should be designed and constructed so as not to obstruct the free flow of the liquid. The transition from small to large pipe diameters must be gradual. As a general guide the length of a concentric taper piece must be 5-7 times the difference in pipe diameters. Sudden reductions in pipe cross sectional area and sharp bends should be avoided especially in the suction or inlet pipework, as these greatly increase the frictional resistance within the pipework. A high frictional resistance within the suction or inlet pipework leads to reduced pressure available at the suction branch. Too low pressure leads to cavitation at the impeller inlet. To prevent turbulent flow into the pump, do not position the shut-off valve in the suction piping adjucent to the pump suction nozzle. The suction valve should be positioned with the handwheel horizontally or vertically downwards to prevent air pockets forming. Install between flow disturbances as fittings or elbows a straight pipe with length of 5 to 8 time pipe diameter. Multi-pump installations should have separate suction pipes to each pump. Excepted are ATTENTION duty and standby pumps which may have common suction pipework since only one pump operates at any time.
4330/e5-1-00-001 page 13 27
F. Cleanin g th e Pipewor k Before a pumpset is commissioned, all traces of foreign bodies and impurities must be carefully flushed out of the supply tank and pipework. Where pipework has been welded, all welding slag etc. must be removed.
G. Suction strainer In order to prevent any of the above impurities entering the pump, we recommend to install a suction strainer made of stainless steel in the inlet pipework. The strainer insert should consists of a supporting strainer (plate with round holes 5 to 8 mm, (0.2 to 0.32 in.) to which a wire screen (wire cloth 0.315 x 0.2 mm, (0.0125 x 0.008 in.) is fixed by welding. The effective area of passage of this strainer must be at least 1.5 to 2 times the pipe ø 0.2 mm 0.315 mm diameter. (0.008 in.) (0.015 in.) Monitor the pressure drop across the strainer by a differential pressure Sketch 5.3-5 Wire cloth gauge. If at any time, a reduction in pump suction pressure is observed, the strainer should be removed and cleaned. The differential pressure 0.35 bar (5 psi.) causes ALARM (clean strainer). At max. 0.5 ATTENTION bar (7 psi.) the pump is SHUT OFF; higher differential pressures may lead to the damage of the strainer result in serious damage to the pump. ATTENTION The given values are limits for the load on the strainer. As NPSH available at the suction branch is reduced by the max. admissible differential pressure at the strainer whereas NPSHavailable has always to exceed NPSHrequired , lower regulation limits for ALARM / SHUT OFF may have to be set accordingly.
H. Pressur e test ATTENTION
The pipework should be pressure tested in accordance with the statutory regulations.
4330/e5-1-00-001 page 14 28
5.4. Ancillary equipment A. Gen eral Ancillary equipment is used to monitor the pump (measuring equipment for pressure, temperature etc.) and to maintain operation (cooling, flushing, sealing etc.). The extent depends on the application and installation requirements. For type, position and dimensions of the ancillary connections please see installation drawing. In case the failure of any auxiliary devices (e.g. cooling, circulation) may lead to an inadmissible pressure build-up in the pump suitable safety devices have to be installed by user (e.g. alarm, emergency shut-down or similar). ATTENTION
Do not mix up connections. After laying the pipes (and also after repairs), check the pipe runs.
The following ins tructi ons may be used as a guide insofar as they apply to the pump as delivered.
B. Electrical c onnections Electrical connections for motors and controlling devices may only be implemented by skilled personnel. The instructions of the electrical equipment manufacturers have to be observed as well as the valid national regulations on electrical installations and the legal regulations of the local power suppliers. The applicable standards and guidelines in respect of terminal connections should be observed. If provided on baseplate the earthing lug must be connected.
C. Pressure measur ing equi pment - The start-up and monitoring of the operating point of the pump is made easier with pressure gauges. See also 6. and 6.7. Pressure gauges should be mounted on a common gauge panel and connected to the tappings in the pump branches or adjacent pipework using a hydraulic tube with an expansion loop. Isolating and vent valves should be installed in the pipework for ease of maintenance. - If case of external flushing of the shaft seal, pressure gauges are installed in this pipes for monitoring the pressure (see 1.4.5).
D. Temperature measuring instruments - If pump operates near the vaporization point of liquid, thermometers are recommended for control of liquid temperature. See also point 5.4 "Minimum flow device". At installation of thermometers in the pipework let submerse the temperature gauge at least 40 mm into the fluid. At pressures over 16 bar use protection tube (DIN 43763). - If technically required, temperature control of circulation fluid for mechanical seal is executed to avoid vaporization in the sealing range (see 1.4.5). - At heating the max. temperature of heat carrier has to be controlled (see 1.4.4). - A measuring possibility of cooling water outlet temperature is favourable, as the adjustment of outlet o temperature smaller than 40 C avoids deposits in the cooling water pipings. - At pumps with high loaded bearings numerous controls of bearing- or oil temperature are required. If necessary control by means of contact thermometer. Execution and measuring points see pipework scheme or installation plan. Limit values see 7.3 and 1.4.2. - It's useful to control temperature under sound insulation covers with tele-indication. Align such a way, that oil- or bearing temperature respectively of pump and driver cannot exceed the permitted limit.
E. Bearing monito ring (Vibration measurement) By means of impact impulse measurement (possible with antifriction bearings), by bearing housing vibration or by shaft vibration measurement. - Advancing bearing damage and other machine failure can be recognised and deteced by means of electronic sensor measurement. This electronic (computerized) vibration system can be used to continuously measure and monitor a variety of supervisory parameters for preventing unexpected machine failure. For further information refer to the manufacturer’s description.
4330/e5-1-00-001 page 15 29
F. Flow indication or flowmeters - According to technical requirements flow indicators are installed in the reflux of supply pipework. Don't start-up pump before auxiliary pipings are open and the liquid stream can be determined on flow indicator. - If there is danger for mechanical seal in case of too low circulation, a flowmeter is installed in the circulation piping, which causes alarm when circulation quantity decreases or which shuts the pump down.
G. Filter / strainer / cycl one separator are absolutely necessary at rinsing of mechanical seal with spoiled rinsing liquid. At tenti on in cas e of operatio n w ith str ainer or fil ter (is not valid in case of cyclone separator). If the pump may not be shut-down for change of filter, switchable, parallel arranged filters are installed. Rising temperature at cover of mechanical seal or inadmissible high differential pressure between measuring points in front of and behind the filter indicate dirty filter. Exchange or clean filter immediately. For operation safety reasons it is recommended to carry out the surveillance of filter not only locally, but also by tele-indicator in the central switch office. ATTENTION
H. Ancillary pipework - Drainage of the pump casing can be effected by leading a pipe into the drip tray of the baseplate or into a collection pipe. Isolating valves must be installed in the pipe and must have a pressure rating at least equal to the rating of the casing. The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to any endangering of operator(s) and environment. - Gland leakage from the shaft seal can also be led into the drip tray or collection pipe. The leakage of dangerous fluids has to be drained or quenched in such a way as to prevent any dangers to persons and environment. - Cooling through cooling liquid: Connections and scope see installation plan or separate drawing respectively. Don't confuse inlet and outlet connection. (Inlet lowest, outlet highest point of cooling chamber). For the adjustment of cooling water quantity regulating valves are installed in the supply pipings. At open system lead the drain pipings over a funnel. - Heating: Connections and scope see installation plan or separate drawing respectively. Don't confuse inlet and outlet connection. (Inlet highest, outlet lowest point of heating chamber). In the supply pipings regulating valves are installed. Lead reflux in a collecting piping, if necessary via steam trap. - Flushing and / or sealing of the shaft seal: Connections and scope see installation plan or separate drawing respectively. For pipings which lead to a heat exchanger, pressure transmitter or supply reservoir, a vent possibility is provided at the highest point. In case of thermosyphon revolution the biggest pipework diameter possible will be used. Supply piping is layed evenly ascending and without sharp bend. - Quench: In case the necessity arises to quench any leakage from the mechanical seal see 1.4.7 for information on quench media and quantity.
4330/e5-1-00-001 page 16 30
5.5. Minimum flo w devic e Note: In accordance local-safety standards these instructions must form part of every operating manual. Safety instructions for pumps which operate in the partial load region. The following information may be disregarded, if the pump supplied never runs in the partial load region.
-------------------------------------------------------------------------------------------------------------------------------------------
General In the partial load region (when operating the pump near zero flow) almost the total pump power is imparted to the flow as thermal energy. If this flow is less than a certain minimum (see 1.4.1), heating will occur and continue until the liquid boils, causing severe damage to the balance device, impellers and casing wear rings leading to eventual breakdown of the pump. To avoid this there must always be a certain flow of liquid through the pump. ATTENTION
If the shut-off device in the delivery pipe is tightly throttled or closed during pump operation, the delivery fluid inside the pump will heat up after just a short time. This may cause the surface temperature on the pump casing to rise above the permissible temperature class. If necessary, provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with emergency switch-off). The following two situations arise for multi-stage pumps with hydraulic balance of the axial thrust: 1. The balance quantity is s uffici ent This means that in cases of relatively low driver power and favourable suction conditions the balance flow is sufficient as the leak-off to be piped away. If this condition applies to the pump supplied, it is noted expressly on the data sheet under 1.4.1 that the minimum flow is equal to the balance flow. The balance pipe must not be connected to the suction casing, but must lead to the suction tank. 2. The balance quantity is i nsuffic ient A device must be fitted in the discharge pipe immediately after the pump, which guarantees minimum flow even with closed discharge valve. The following devices have proved successful in use: a)
Aut omatic leak-off non-return valves operate such that as the flow decreases the minimum flow line automatically opens and an integral throttle element controls the minimum flow. The contrary happens on increasing the capacity. The minimum flow line is directly flanged to the automatic leak-off non-return valve and leads back to the suction tank.
b)
Constant by-pass. A by-pass line is fitted between the pump and the discharge valve, which also leads back to the suction tank. A throttle is built into the pipe which determines the flow rate. With this type it should be remembered that the by-pass quantity also flows with the discharge valve open, which reduces the efficiency of the pump. It must be considered carefully whether it is worth buying an automatic leak-off non-return valve.
Minimum flow line or by-pass The minimum flow line is not supplied by the pump manufacturer. It must be provided by the operator. The pipe must always lead from the pump to the suction tank. For shutdown and disconnection for maintenance, a shut-off valve must be fitted in the minimum flow line, but must be locked open before commissioning. If several pumps are installed to operate in parallel and the minimum flow pipework connects into a common header, it is necessary to install a non-return valve in each feed piping. ATTENTION
ATTENTION
Separate pipes must be laid for minimum flow pipe and balance pipe if both are required to be led back to the suction tank. minimum flow line
Never operate below pump ATTENTION minimum flow. Minimum flow operation causes in higher internal wear therefore operation at minimum flow should be maintained for no longer than 2 hours in any 24 hours of operation.
4330/e5-1-00-001 page 17
Minimum flow valve
Suction tank
Sketch 5.4-1 T ypical piping layout for minimum flow line 31
6. OPERATION 6.1 General The following recommended start-up and operating procedures apply to the pump only. For information on any equipment (driver, shaft coupling, shaft sealing system ...) refer to manufacturer’s instructions.
Safety information Do not start or operate the pump, - unless the installation has been verified to be correct and all safety and control functions have been checked. - unless you have a complete understanding of the location and function of all components of the pump aggregate including valves and any upstream and downstream equipment that my effect the flow of medium to or from the pump. - unless you have a complete understanding of the all auxiliary mechanical, electrical, and hydraulic systems as well as the f unction of all monitoring gages and warning devices. When starting the pump, be prepared to execute an emergency shutdown in case of failure of the pump or auxiliary system.
6.2 Commissioning Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. ATTENTION
The items described individually have to be carried out, as far as applicable, step by step during commissioning.
With electric drive it has to be assured by qualified personnel that the necessary protection measures work. Earthing, reset, residual current failure operated device etc. have to be ready for service acc. to approval by skilled personnel.
Before commissioning a. Connections Check bolted connections and plugs. Inspect ancillary pipework for correct installation. b. Lube Rinse bearing housing with light oil and allow to drain. Fill with lubricating oil, see also 1.4.2 / 7.3 and table recommended lubricants. c. Alignment Check alignment of coupling (see 5.2) d. Shaft seal Check shaft seal (see 7.2). In case of double acting mechanical seal fill and vent sealing system (refer to manufacturer’s instruction). ). e. Filling the pump In case of hot (or cold) product: extreme caution must be exercised when filling a pump that is ATTENTION at ambient temperature. To prevent thermal shock the pump should slowly and controlled 3 filled up with small fill up rate 0.3 to 0.5 m /h (1.2 to 2 gpm) so that the pump case and internals can be warmed up (or cooled down) uniformly. Filling the pump - feeding operation Filling the Pump - suction lift • •
•
•
•
Slowly open shut-off valve in inlet line
•
If existing (see installation plan) Open vent (not valid for self-venting casing) In case of mechanical seal: Shaft sealing chamber has to be vented (see also 5.4 Flushing and Sealing) As far as existing: Close vent when pumped medium flows without bubbles Fully open shut-off valve in inlet line
ATTENTION
•
• •
If existing (see installation plan): Open vent (not valid for self-venting casing) In case of mechanical seal: Shaft sealing chamber has to be vented (see also 5.4 Flushing and Sealing) Fill pump (suction pipe must have foot valve) As far as existing: Close vent when pumped medium flows without bubbles
Before starting the pump, the suction piping, pump case and shaft seal chamber must be completely filled with liquid.
If there is danger of frost, protect the pump casing, bearing housing and cooling chambers against freezing. Minimum flow line (if fitted) Open and lock the valve in the minimum flow line (see also 5.4 - para. Minimum flow device).
ATTENTION f.
•
Fully open shut-off valve in suction pipe
M000/e6-1-00-000 Page 1
32
g. Balance line If the balance line is returned to the suction tank, also open and lock the valve in this line. (see Installation Plan or P & I Diagram).
6.3 Pump start-up and Operation Pump operation is based on the assumption that the pump system is always completely full of delivery fluid. This prevents the existence of any potentially explosive mixture in the pump. If this is not guaranteed, appropriate safety systems (e.g. liquid detectors or motor load controllers) must be provided on the equipment. a.
Ancillary equipment If available, put ancillary equipment into operation (e.g. cooling, heating, sealant pressure...), open the valves in the ancillary pipework (open Quench after pump start-up), vent pressure gauge (see also 5.4).
b. Start-up with non-pressurized system •
•
•
Start-up with pressurised system
Close shut-off valve in the discharge pipe (minimum flow must be guaranteed).
(precondition is non-return valve in discharge pipe)
Start driver and bring the immediately to operating speed.
•
pump
rotor
Open discharge valve slowly, until the differential pressure drops to the value given on the data sheet.
Start driver with open discharge valve and bring the pump rotor immediately to operating speed
ATTENTION
Operation below min speed e.g. by variable speed drive or turbine drive, causes serious damage to the pump.
ATTENTION
Pump should produce pressure at discharge as soon as rated operating speed is reached. If not, shut down immediately and vent pump system.
Warning: The differential pressure must not fall below the design point even with plants with fluctuating system pressure. Note: The pressure gauge on the discharge side shows the differential pressure plus the suction pressure.
c. Observe ammeter reading The full load amps given on the rating plate of the motor must not be exceeded. d. Adjustments The pump capacity can be adjusted by the discharge valve. ATTENTION
Do not operate pump below minimum flow (see 1.4 and 5.4 Minimum flow). During pump operation the valve in the suction line must be fully open.
Non-observance may result in an unacceptable temperature increase and cause the pump to run dry. In extreme cases the pump casing may burst.
Starting of a Stand-by pump or starting a Parallel w orking pump Note: If a stand-by pump should replaces the function of another one (operating pump), both pumps have to run parallel for a short time.
a. Proceed preliminary work for the stand-by or parallel working pump as given in section 6.1 General and 6.2 Commissioning. b. Start-up pump as given in 6.3, check discharge pressure. Operate both pumps parallel. c. Stand by pump After running in full operation the first operating pump can be shut down. Refer to 6.5 shut down. Parallel working pumps Both pumps remain in operation. Each (identical) pum p deliver only half of capacity delivered, see pump curves below. Non-identical pumps can also operate in parallel but selection must be done very carefully.
) m ( n i d a e H
single pump curve
two identical pumps working parallel
3
Capacity in (m /h)
4000/e6-0-00-000 page 2
33
6.4 Inadmissible operating modes
Overloads have to be avoided by all means as they may lead to a failure of parts due to too stringent mechanical requirements. Overloads occur, if the pump is run beyond its original application range, i.e. exceeding of the max. admissible speed remaining of the min. speed (low speed rotation e.g. by turbine drive, high velocity flushing through the pump, damage of discharge non-return valve causes serious damage to the pump) exceeding or remaining of the medium viscosity exceeding of the max. admissible inlet pressure exceeding of the max. admissible temperature exceeding or remaining under the operating range of the pump running of the pump without proper venting of pump interior running of the pump without required safety devices ( safety valves, electrical overload protection etc.) operation of the pump with closed or strongly throttled shut-off device in the discharge line without having a minimum flow device (exception: during start-up). operation of the pump with closed or throttled shut-off device in the inlet line (dry running) operation of the pump for the delivery of fluids, for which the pump are not suitable (chemical, solids, gas content ...) operation of the pump with wrong sense of rotation operation of the pump with inadmissible bearing lubrication or with wrong lubricant Operating modes like that and other inadmissible operating modes may lead to heavy damage on the pumps and other parts of the plant. Danger may arise by the bursting of pressure-holding parts and people within the range of danger may be hit by pieces or fluid, which may be hot, aggressive or toxic, as the case may be. There may be mortal danger.
6.5 Shut-down
(observe sequence)
Remark: If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shutdown is for a short time only. For lengthy shut-downs, for repairs and where there is no non-return valve, the discharge valve must be closed. a. Close discharge valve slowly and top the driver, when doing this pay attention to whether the rotor runs down smoothly. Standby service Ancillary systems as cooling- , sealing- and quench systems are operational. Standby pumps should be started at regular intervals to ensure their readiness for immediate service. We recommend to start-up the pump unit once every month and run for 30 minutes. Extended shut down b. If the pump works on a suction lift and is not to be left ready for start-up, the suction valve should also be closed. c. If existing, close quench piping. d. If fitted, close the valves in the ancillary pipes with the exception of the cooling water, which should only be switched off when the pump has cooled down. Freeze damage, preservation e. If there is danger of frost, prevent liquid from freezing within pump. Drain all cooling jackets, including external heat exchangers and pipings.
Emergency shut down of the pump a. In case of failure of the pump or any auxiliary system shut down the driver immediately. b. Before restarting the unit once again follow 6.6 Restart procedure
6.6 Restart procedure If the pump is switched off by emergency shut down or trip, do not restart before the causes of the emergency has been found and removed. a. Before restarting, check that the pump shaft is at a standstill. If the non-return valve in the discharge pipe is leaky, the pump shaft may rotate in reverse direction due to the backflow of the medium delivered. The pump must not be switched on when the pump shaft is rotating in reverse direction, as this may damage the pump. b. Proceed restart as given in section 6.3 Start-up and operation. ATTENTION
4000/e6-0-00-000 page 3
34
6.7 Service Control General A pump must be looked after and carefully supervised to ensure trouble free running. During the first period of operation (24 hours) supervision should be intensive. Read and check the operating parameters every hour. During the next period of operation (first week) supervision should be done every 24 hours. During normal use checking should be done together with the regular inspections at least ones a week. ATTENTION
If any vibrations, unusual noises or faults are observed stop the pump unit at once. Refer to section “Operating faults”.
Number of starts The pumps are designed for continuous operation. Too many and too frequent starts can accelerate ageing and result in abnormally high wear and short life time. In case of many starts we recommend an intensive supervision and maintenance intervals should be shortened. The recommended number of start-ups are as following: - Commissioning phase: up to 200 start / stops (max. 6 starts / day) - Commercial operation:
up to 3 starts / day Cumulated number of starts max. 600 starts / year
Remark: In case of many start / stop cycles we recommend to perform a general overhaul of the pump after 6 years running time.
Checking the duty point (design point) of the pump Particularly important at the initial start-up: •
Check the speed.
•
Read the discharge pressure and subtract the suction pressure.
Convert this pressure (generated pressure) to a head and compare it with the generated head shown on the pump duty plate at the corresponding speed. generated pressure (bar) x 10 200 generated head (m) =
3
density of liquid (kg/m ) Metric units
3
generated head (m) x density of liquid (kg/m ) generated pressure (bar) =
10 200
The generated pressure must not fall below the value given in the pump data sheet, otherwise the maximum allowable capacity could be exceeded, the driver could be overloaded or the suction pressure could fall below the minimum required by the pump.
ATTENTION
Checking the capacity
pump characteristic curve
The capacity is determined from the pump performance curve and the generated head (m) as calculated above.
Operating range
Find the calculated value of the generated head on the vertical axis of the performance curve.* Draw a horizontal line through this point until it intersects the curve. The corresponding capacity is read on the horizontal axis vertically below the point of intersection. * If the characteristic curve sheet only includes the pressure of one stage divide head by number of stages of the pump supplied.
) m ( n i d a e H
y t i c a p a c m u m i x a M
y t i c a p a c m u m i n i M 3
Capacity in (m /h)
4000/e6-0-00-000 page 4
35
6.8 Operating faults Hydraulic or mechanical causes can seriously affect the operation of a pump. There are other justifiable operating faults in the plant. There is usually a certain connection between the different types of faults. It is, therefore, expedient to list and compare the symptoms as well as the possible causes. Assistance can be found for individual operating faults in virtually all cases.
Symptoms / Possible causes of faults / Remedies Symptoms
Possible causes of faults
Remedies
1 Pump does not work. No discharge pressure. (Failure at start-up)
Driver out of service, speed too low
Check - refer to manufacturer‘s manual Check and correct Check-refer to pump rotation arrow Vent pump Inspect and correct Inspect foot valve Inspect pump internals Fill the system Check operating data (1.4)
Rotor blocked Wrong direction of rotation Pump not primed Suction valve/line blocked Foot valve blocked or damaged Impeller passages blocked 2 Loss of discharge Suction pipe not completely full pressure after start-up Too much air or gas in the pumped liquid Leakage of air into pump suction 3 Pump flow too small. Suction or Discharge valve not f ully Differential pressure open too low. Suction strainer blocked Efficiency loss Minimum flow line open, minimum flow valve damaged or bypass orifice worn Furring of the pump internals and/or pipework Impeller passages blocked Pump internals worn (gap clearances) 4 Pump vibrates or causes too much noise
Coupling alignment faults Worn shaft coupling Suction valve not fully open Suction strainer blocked Pump runs with cavitation Piping strain, excessive high nozzle forces and moments Foundation too weak, base not or not correctly grouted Impeller damaged or blocked Bearings damaged Unbalanced rotor – causes vibration Shaft bent
4000/e6-0-00-000 page 5
36
Check and correct (seal) Check valve position and correct as required Disassemble and clean strainer Check minimum flow line, minimum flow valve, bypass orifice (5.4) Clean and flush pipework. Disassemble and clean pump internals. Disassemble and inspect pump internals Disassemble and inspect pump clearances (8.) Check coupling alignment (5.2) Check coupling condition and replace Check and correct (open fully) Disassemble and clean strainer Check operation data (1.4). Create more pressure at the pump suction. Piping should be properly supported to prevent strains from being imposed on the pump Inspect foundation bolt tightening and baseplate grouting (5.1) Inspect pump internals Disassemble and replace bearings (8.) Check balance of coupling, driver and pump rotating parts Disassemble and check shaft runout (8.)
Symptoms
Possible causes of faults
Remedies
5 High shaft seal temperature. High leakage of mechanical seal. Short shaft seal life
Seal flush insufficient (flow rate) or missing Wrong orifice size or worn orifice Solids block seal rings/springs
Check flow requirements
Vaporisation in the seal ring area Seal fluid not suitable (abrasive) Seal rings, auxiliary gaskets (O-rings) or springs damaged Dry operation of seal. Seal system not correctly filled or vented Seal face material inadequate
6 High bearing temperature. Short bearing life.
Pump shaft bent Pump not running at operating point Coupling alignment faults Too much grease or oil in the bearing Oil level too low or high Wrong lube oil quality Bearings loaded during assembly Insufficient bearing cooling (air / water)
Bearings damaged Excessive pump thrust
Shaft bent 7 Lube oil leakage
8 Excessive wear of pump internals - Corrosion - Erosion - Loss of material 9 Pump overheating/seizure
4000/e6-0-00-000 page 6
Oil level too high Labyrinth seal or shaft seal ring improperly installed Bearing cover gasket or seal damaged Vent blocked Pump not running at operating point Insufficient suction pressure. Operating fluid differs from specified value (temperature, specif. gravity...) Materials of construction not compatible with medium delivered Operating below minimum flow (pump dry running)
37
Check size, flow requirements Disassemble and remove solids, review application Check circulation flow or cooling requirements (1.4, 7.2) Review application, install filter or separator Disassemble and replace damaged seal parts (8.) Fill and vent shaft seal chamber/system Review application with seal manufacturer Check shaft runout at seal area Review operating parameters (1.4) Check coupling alignment (5.2) Check and correct (7.3) Check and correct oil level (7.3) Verify that recommended lubricant is used (7.3, T 3). Change lube oil. Examine assembly and condition of bearing and associated parts (8.) Check air intake (environmental temperatures under noise hoods). Check cooling water requirement (1.4) Disassemble and replace bearings (8.) Check hydraulic balance device, balance pipe. Disassemble and inspect pump internal clearances (8.) Disassemble pump and check shaft runout (8.) Check and correct oil level (7.3) Examine assembly (labyrinth leakage bore downwards) Disassemble and replace gaskets/seal (8.) Check and clean vent connection Review pump operating parameters with a Sulzer representative, make necessary correction to unit design. Refurbish pump with correct parts, clean system. Assemble filter or separator. Review hints for minimum flow. (1.4, 5.4) In case of seizure disassemble and repair unit.
7. MAINTENANCE 7.1 Pump general Prior to and during the work ensure that the atmosphere is not potentially explosive. Stop all work immediately if any danger arises. The operating personnel shall inspect the machine frequently. The purpose of the inspection is to thoroughly familiarize personnel with the equipment. This is imperative if abnormal occurrences are to be detected and remedied in time. It is vital that the inspections cover the following points: 1. Leakage Check main connections on pump suction and discharge Check leakage on shaft sealing, auxiliary connections Check for oil leakage on bearing housing >
>
>
2. Gauges
Check pressure gauges (pump suction, discharge, ...) Check temperature (fluid, bearings, driver, ...) Check ammeter (motor)
>
> >
3. Bearings
Check the bearing temperature Feel the bearing vibrations (measure the SPM- values) Check the oil level, refill constant level oiler
>
> >
4. Vibration, Noise
Feel the machine Check for undue vibration Check for unusual noises
>
> >
5. Fastening elements
Check that all screw fasteners are correctly tightened
>
Safe operation can only be guaranteed if the pump unit is kept in perfect technical condition. This, in turn, can only be achieved through constant monitoring and proper maintenance. ATTENTION
If any vibrations, unusual noises or faults are observed stop the pumpunit at once. Ascertain the cause and rectify (see Operating faults).
Monitor ancillary equipment during operation (if fitted) Gauges: Cooling: Flushing/Sealing:
pressure, temperature, ammeter at regular intervals flow and temperature pressure, temperature, (quantity)
Any deterioration in pump performance not caused by alteration or furring of the pipework is probably due to wear of the pump internals. The pump should be taken out of service and overhauled. See section 8. for details on overhauling the pump. The pressure in the balance chamber should always remain constant. If the balance pressure increases by 2-3 bar over the pressure when the equipment is new, the balance device must be checked for damage. In most cases it will be necessary to change the balance parts. The increase in balance pressure can, however, also be attributed to the increase in resistance in the balance line due to furring. ATTENTION
Bearings For information about lubrication see chapter 7.3. Bearing housings has to be kept clean on the outside, since the radiation of heat is reduced by deposits of dust or dirt. Bearing monitoring: Check the bearing vibration during running. In case of antifriction bearing, by means of shock impulse method. Carry out checks according to the operating instructions of the measuring gauge in fixed intervals. During first start-up the initial values must be recorded to find out deviations of later measurement. After measuring put coloured caps on measuring nipples distinguishing, green cap
=
everything o.k
yellow cap
=
increased attention
red cap
=
beginning bearing damage
>
>
>
With correct maintenance and unhindered heat dissipation, it is possible – in the area of the rolling o bearings - to maintain temperature class T4 (135 C) at the surface for ambient temperatures up to o +40 C. Special measures (cooling) must be taken for higher ambient temperatures, or for o o temperature classes T5 (max. 100 C) and T6 (max. 85 C).
0000/e7-1-01-000 page 1
38
Vibrations These can be detected by hand or with electronic equipment (frequency or amplitude analyser). Horizontal pumps, which are fastened to the foundation with anchors should not exceed a vibration speed given in the following table. Bearing vibration level unfiltered RMS / 10-1000 Hz -1 -1 Operating speed up to 3000 min up to 3600 min Continuous operation Alarm at Shut off aggregate ATTENTION
4.5 mm/s 7.1 mm/s
(0.18 In/s) (0.28 In/s)
5.6 mm/s 9.0 mm/s
(0.22 In/s) (0.35 In/s)
11.0 mm/s
(0.43 In/s)
11.0 mm/s
(0.43 In/s)
This values are valid for operation at rated point / preferred operating range (from >70% Flow to <120% BEP) only.
Flow < 70% BEP - part load operation acceptance criteria: +1.5 mm/s (0.06 In/s) RMS compared to the value for preferred operating range. Measured values which are too high can also be caused by the plant (pipings/accessories) or by other vibration sources (machines). In order to determine the reason for high vibration values a vibration analysis is necessary.
Noise Some abnormal noises can be heard immediately, such as those due to rolling element indentations because of improper mounting; others are progressive. Noise is usually an indication of incipient failure and varies in intensity and frequency with the extent of dam age.
Alignment During shut-down (according to operating requirements) check the alignment of the coupling (at least once a year ). Re-align if necessary (see 5.2).
Operating log It is recommended to enter operating data and data on lubrication, repairs etc. in an operating log. An ongoing operating record will assist troubleshooting and machine service decisions. Analyse machine performance regularly.
Spare parts It is recommended that spare parts listed below are always kept in stock. This modest investment can often prevent minor faults from developing into serious trouble. The following parts should be stocked: Antifriction bearings, in case of plain bearing (set bearing shells, pads)
>
Balance drum and liner (set balance discs)
>
Wear rings and setscrews
>
Gaskets and O-rings
>
Mechanical seals
>
For pumps used in extremely important service or if several identical machines are operating in the same plant, it is recommended that a complete machine be stocked at job site. Orders for spare parts should always include the following information: Type of pump (rating plate or operating manual)
>
Order number (rating plate or operating manual)
>
Quantity and designation of parts / article-number (parts list)
>
Part number (parts list or sectional drawing)
>
Pump safety can only be ensured if repairs are carried out by expert specialist personnel using original replacement parts.
0000/e7-1-01-000 page 2
39
Inspection and check list The intervals between the necessary overhauls may vary extraordinary, as the differing operating conditions can have substantial influence on the service life of machine parts. Under normal operating conditions and with pumps which are not neglected in maintenance and care, the check and overhaul works are recommended in the following intervals. Further recomm. see y l k y e l i a e D W
Measuring devices (Pressure gauges, thermometers ammeters as far a existing and not monitored by automatic switches alarm/emergency out)
Pressure
Temperature
1.4.1 / 6.7
>
Balance chamber
4.2 / 7.1
>
Medium delivered
1.4.1
>
Pump bearing / oil sump
7.3
X
y l h t y n l o r m a e 6 Y
l u a g h n r i r e u v D O
Delivery pump (suction and discharge)
>
y l h t n o M
X
Further checks and inspections Oil level
>
Oil sight glass / Constant level oiler
7.3
X
Leakage
>
Shaft seal / Mechanical seal cover
7.2
>
Flange sealings (main connections)
-
X
>
Lubricating oil from bearing housing
-
X
>
Vibration measurement
7.1
>
Bearing shock impulse
5.4 / 7.1
Vibration
Maintenance works Oil change
>
Bearing housings
1.4.2 / 7.3
Coupling
>
Check alignment
5.2
Bearings, balance drum and liner, shaft seal, impellers, wear rings ...
8.
General overhaul / wear check
>
These parameters should be recorded in an operating log and used as a basis for maintenance works.
Overhaul allows supervision of wear, early recognition of any sign of damage and replacement of defective parts in time. All signs of wear and spare parts used should be recorded in the operating log.
0000/e7-1-01-000 page 3
40
Title:
Report
Supervision check list
Plant / Location:......................................................................................................................................... Aggregate Specification:........................................................................................................................... Pump type:..............................................................
Driver:..............................................................
Serial-No.:...............................................................
Type / No.:.......................................................
normal
abnormal
Remark:...........................................................
Run
........................................................................
Noise
........................................................................
Vibration
........................................................................
Start-up
........................................................................ Comments:................................................................................................................................................. ................................................................................................................................................................... ................................................................................................................................................................... TIME
Gauges
Bearings o
Pump Start up
Shut down
Suction
Temp. C
Discharge
Balance
Remark:
ND-side
D-side
ND-side
R 0000 / 7-0-00-001 Date:
0000/e7-1-01-000 page 4
D-side
Oil level
Sign:
41
Page ... of ...
Title:
Report
Inspection check list
Plant / Location:....................................................................................................................................... Aggregate Specification:......................................................................................................................... Pump type:..............................................................
Driver:..............................................................
Serial-No.:...............................................................
Type / No.:.......................................................
1. Leakage
normal
abnormal Remark:.....................................................
Pump suction
..................................................................
Pump discharge
..................................................................
Shaft seal
..................................................................
Remark:.....................................................
2. Gauges Pump suction
..............
bar
..................................................................
Pump discharge
..............
bar
..................................................................
Balance chamber
..............
bar
..................................................................
3. Bearings
normal
abnormal
Temperature
.................................. C D-side / ND-side
Oil level
................................... O.K. Yes / No
Oil refilled
................................... Refill QTY. liters
Oil leakage
................................... Yes / No
normal
abnormal
..................................................................
..................................................................
Pump casing
.................................................................
Noise
.................................................................
4. Vibration / Noise Bearing hous. D-side
ND-side
o
Remark:.....................................................
.................................................................. Comments:............................................................................................................................................ .............................................................................................................................................................. .............................................................................................................................................................. Remark:
R 0000 / 7-0-00-002 Date:
0000/e7-1-01-000 page 5
Sign:
42
Page ... of ...
Title:
Report
Maintenance list
Plant / Location:....................................................................................................................................... Aggregate Specification:......................................................................................................................... Pump type:..............................................................
Driver:..............................................................
Serial-No.:...............................................................
Type / No.:.......................................................
Maintenance interval No.: .......
Operating hours: .........h
Number of starts: ........
Bearings:
Lubricating oil change
Lubricant type : .........................................
Leakage checked
Quantity: ...................................................
Bearing monitoring:
Green
Yellow
Red
Drive side:
Non-drive side:
everything o.k.
attention
damage
by impact impulse measurement Comments:
......................................................................................................................
Mechanical part:
Coupling alignment checked (reported)
Bearings opened and checked
Mechanical seal checked
Balance device opened and checked
General overhaul with pump hydraulic part opened and checked
Rotor newly adjusted (axial / radial center position)
Parts changed:
Mechanical seal - Drive side / Non-drive side
Balance device
Bearings - drive side / non-drive side
Shaft
Wear rings
others: ..........................................
Comments:.............................................................................................................................................. ................................................................................................................................................................ ................................................................................................................................................................ Remark:
R 0000 / 7-0-00-003 Date:
0000/e7-1-01-000 page 6
Sign:
43
Page 1 of 1
7.2 Shaft seal Single-acting mechanical seal General remarks Mechanical seals intended for use in potentially explosive areas must satisfy the “Ex” protection requirements. In the case of mechanical shaft seals the exit of the medium delivered is prevented by two plane parallel lapped ring surfaces which are pressed together with the help of spring force and liquid pressure. Seal rings (stationary and rotating) are sealed against adjacent pump parts with the help of adjoining sealings (as for example O-rings) serving simultaneously as elastic bearing.
Conditions ATTENTION -
In order to have trouble-free operation a liquid film has to form between the slide faces and therefore the following conditions have to be fulfilled by the medium delivered:
sufficient lubricating properties evaporation temperature considerably higher than operating temperature no impurities in the slide ring region
If auxiliary facilities like - flushing - blocking - heating - cyclone separator/filter (in case of an impure medium delivered) are necessary for arriving at the operating conditions required the details given in paragraph 1.4.3 / 1.4.4 / 1.4.5 / 5.4 and in the installation plan of the pump have to be observed. Failure of an auxiliary device (cooling, circulation, etc.) may cause the temperature of the casing surface to rise to an unacceptable level. If necessary, provide the equipment with appropriate safety systems (e.g. remote temperature monitoring with emergency switch-off).
Maintenance The maintenance of the mechanical seal can be limited to the control of the auxiliary facilities, leakage and temperature at the mechanical seal cover. In the case of normal flushing by circulation the seal cover must not reach any higher temperature than the adjacent pump casing. In the case of cooling or heating the data mentioned in paragraph 1.4 have to be observed. A slight leakage of the mechanical seal is normal. It is impossible, however, to make special ATTENTION statements with regard to the leakage of the mechanical seal, as the quantity of leakage depends on a lot of different factors (e.g. size, material, liquid pumped, temperature etc.). In case of high leakage seal ring pairs may also leak. In this case defective parts have to be replaced. Auxiliary seals (such as O-rings) have to be renewed during each assembly. Mechanical seal rings (stationary and rotating) have always to be replaced as a unit.
0000/e7-2-01-002
44
7.3 MAINTENANCE - BEARING / LUBRICATION An ti -fr ic ti on bear ing with rin g oi l lub ri cat io n General Centrifugal pumps are often exposed to heavy stress caused by continuous operation and heavy forces (radial, axial). Therefore a proper oil quality is a prerequisite for a long bearing life and trouble-free operation. The oil must not contain any foreign substances, acids or resins. Minimum requirements of suitable lubrication oils are given in DIN 51 511, API-SF/CC, MIL-L-46152 B . All lubricating oil suppliers are therefore in a position to classify their products accordingly and to propose a product which satisfies these standards. ATTENTION
Oil viscosity Since, with anti-friction bearings, the self-heating of the bearing due to filling plays an important role, and 2 since, on the other hand an oil viscosity of at least 12 mm /s at operating temperature of the bearing is required for a sufficient lubrication film, the oil viscosity has to be selected as follows: Multigrade Engine Oil SAE 15W-40 should be used. The max. allowable temperature values are given in the table below. In case of deviations contact the service. If the temperatures o after overhaul rises over the given values for continues operation (> 90 C in the oil sump), as a first measure check thrust bearing axial clearance (see 7.6). ATTENTION
Change intervals and oil quantity In case of first commissioning or of an overhaul, change the oil after 10-15 hours of operation. If further pollution by foreign substances and water is low, change intervals of 6 months or 4000 operating hours can be adhered to. Pump si ze
40-180
Oil filling in liters per bearing hou sing
50-220
0.6
80-260
100-300
0.9
150-360
200-400
1.6
Check regularly the oil level in the bearing housings (oil sight glass). In the case of automatic constant–level-oilers pay attention to refill the reservoir (oiler tank).
Max. allowable temperatures Measuring spo t externally at bearing housing near bearing
Mode
at external bearing race
o
< 110 C
o
> 120 C
o
> 130 C
Continuous operation
< 100 C
Alarm at
> 110 C
Switch off aggregate
> 120 C
in the oil sump
o
< 90 C
o
o
> 100 C
o
> 110 C
o
o
Check temperature at the measuring spots regularly Suitable lubricators of different brands see lubrication recommendation T3 annex
4330/e7-3-01-000 Page 1
SAE 15W-40 45
Recomm ended Lubr icants
T3
Proper lubrication is particularly important for the operational safety of centrifugal pumps. If suitable lubricants are correctly applied, an optimum performance is obtained and trouble and its consequences are avoided. Supplementing the operating instructions, the table gives the lubricants which are recommended for the lubrication of centrifugal pumps which are suitable for an ambient temperature o o between -10 C and +40 C. The lubricants have been listed in alphabetical order which does not say anything about their quality.
Supplier
Multigrade Engine Oil SAE 15W-40
AGIP
F1 SUPER MOTOR OIL, SINT 2000
ARA L
SUPER ELASTIC MOTOROIL 1540
BP
BP SB MOTOROIL, VISCO 2000
Castrol
GTX 2, GTX 3, TXT SOFTEX CASTOLITE
DEA
REGIS MULTIGRADE, TORUS 15W40
ELF
PRESTIGRADE, SPORTI T, MULTIPERFOR. 3C
ESSO
ESSOLUBE MHC 1540, MHX 1540
MOBIL OIL
SUPER FORMULA, DELVAC SUPER 15W40
SHELL
HELIX STANDARD, ROTELLA MX 1540, RIMULA TX
TEXACO
HAVOLINE, URATEX MULTIGRADE 15W40
WINTERSHALL
TFE 10W40, MAGNUM SL, MULTI RECORD 15W40
4330/e7-3-01-000 Page 2
SAE 15W-40 46
Oil level The center of the sight glass (if present) indicates the minimum oil level required in the bearing housing. During standstill of the pump the oil level is to settle higher; during operation the oil level sinks towards the centre of the sight glas s. Monitoring oil level. A sudden oil level drop can indicate a leak. Stop operation and inspect unit. ATTENTION
Oil replacement Warning: Lubeoil can cause skin irritation and eye inflammation. Follow all safety precautions specified by the manufacturer. For oil replacement proceed as follows: 1. Shut down pump. 2. Put a tray under oil drain to catch the whole quantity of oil securely. (Position of the oil drainage bores and size see installation plan or dimension sheet.) 3. Remove screw plug, drain oil thoroughly. Tighten screw plug again securely. 4. Fill bearing bracket with fresh oil as described. Dispose of used oil according to statutory regulations. Do not put into wastewater by any means.
Filling-in of oil with constant level oiler (Non Adjustable Type)) Remove oil filling plug at the top of the bearing housing. Fill oil through the bearing-housing fill opening until the casing of the constant level oiler begins to fill up (swing back oiler bottle to check oiler case filling). Then fill the bottle with the same oil and swing it back to its working position. Repeat this procedure until a minimum of 2/3 of the bottle remains filled up. Screw in and tighten filling plug. Maintenance: Check the supply in the bottle at times and refill, if neces sary.
Constant level oiler working principle When the oil level within the bearing housing drops, the opening to the supply bottle gets free. Oil flows from the supply bottle until the former oil level is reached and the opening to the supply bottle is covered by the oil level.
Oil bottle swinged back
Oil bottle in working position
refill here
Oil level
casing
gasket
ATTENTION
0000/e7-3-01-002
Make sure that the glass bottle is tightly closed, if necessary replace gasket. Turn bottle handtight into threaded cover.
47
8.1
OVERHAUL - DISMANTLING OF THE PUMP
When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts) well beforehand to minimise the down time. When ordering spare parts it is essential to give an exact description of the part, its part number, the pump type and serial number (see the duty plate). References Refer to specific drawings (section drawing(s), parts lists, installation plan). Note: A pump should only be disassembled by qualified specialists with suitable tools and by strictly observing the instructions.
Preliminary wor k -
Close the suction and discharge valves and secure them against unauthorised opening.
-
Let hot pumps cool down to ambient temperature before disassembly.
-
Isolate the driver to prevent start-up. With electrical driver: Remove residual current (take away safety fuses). Have electrical connections disconnected by an electrician.
-
Drain the pump (position of drain screw see installation plan) The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to any endangering of operator(s) and environment. Observe legal provisions for disposal.
In case the pump delivered aggressive, toxic or otherwise dangerous media, it has to be flushed carefully, to be cleaned on the outside and to be decontaminated in the case of radioactivity. If the pump is sent to the manufacturer to be repaired, the cleaning / decontamination has to be carried out before transport. The service personnel will have to be careful however inspite of this, as even in the case of a thorough flushing and cleaning, residues of the fluid may leak out. -
Remove the coupling guard and separate the coupling halves.
-
Remove any instruments and ancillary pipes.
-
Drain off oil from bearing brackets.
Dispose of used oil acc. to legal regulations. Never put it i nto the sewage system. - Disassemble pump and take it to assembly site. Pay attention t o hazardous situations during disassembly, i.e. take care to stand firm , secure assembly parts against droppin g, support or prop loose parts etc. -
Remove coupling half on pump side (see sketch 8.1-1), take off key (940...)
To avoid damage to the bearings or to the shaft centering thread use a suitable puller and protect the shaft centering thread by a disc. The bearings must by no means be subjected to any pressure or shock.
ATTENTION
Sketch 8.1-1 4330/e8-1-01-003 Page 1
48
Dismantling of bearing - non-drive side -
Remove screws (900.01) for the fastening of the fan cover (832.01) and take off fan cover. Take circlip (932.01) out of shaft groove by means of spring ring pliers, push fan (831.01) off the shaft and remove key (940...).
-
Loosen setscrew (904.06) of thrower (507.05) and push thrower off the shaft. Remove carefully any burrs caused by setscrew.
-
Remove hexagon socket screws (914.02) from bearing cover (360.02) and take off bearing cover.
-
Remove shaft nut (920.16 or 920.15 depending on model). Shaft nut (920.16): Locking pins pressed against the shaft by the adjusting screws, are in the bearing fastening nut KMT (920.16). As the locking pins were fitted into the bearing nut by pressure fit, the bearing nut will still rest tightly on the shaft thread after loosening the adjusting screws. Light tapping on the shaft nut near the screw holes will loosen the locking pins a little so that the shaft nut can be screwed off easily. Shaft nut (920.15): Bend lockwasher tang out of bearing nut (920.15) and screw off bearing nut. Take off lockwasher (931.01) and distance disc (551...).
-
Take off lockwasher (931.01) and oil ring (644.01). Push spacer sleeve (525...) off the shaft.
-
To dismantle the bearing bracket, remove dowelling (tapered pins, 560...) on bearing bracket. Screw in (tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws 901...) on the bearing bracket flange.
ATTENTION
Arrest the shaft before drawing off the bea ring bracket on non-drive side to avoid damage to the mechanical seals. To do so mount a holding device on the drive side to fasten the rotor to it by means of the shaft bore, see sketch 7.1-2.
Draw off bearing bracket wi th puller: Push bearing bracket together with antifriction bearings evenly off the shaft.
Arresti ng th e roto r on dri ve (turbi ne) side: Replace 2 fastening screws from bearing cover opposite to each other by the holding device and secure the rotor by the shaft centering thread.
puller
holding device
shaft
Bearing bracket drive side
Bearing bracket non-drive side
shaft
Sketch 8.1-2 - Screw off hexagon socket screws (914...) of the bearing bracket fastening, mount puller (see sketch) and draw off bearing bracket together with antifriction bearings (320.02). Dismantle antifriction bearings. - Push inboard thrower (507.06) off the shaft.
- Screw off hexagon nuts (920.02) and loosen and remove bearing bracket lantern (344.01). If present (see sectional drawing).
4330/e8-1-01-003 Page 2
49
Removal Removal of bearin bearin g - driv e side -
To disassemble the bearing bracket drive side remove holding device again (mounted for dismantling the bearing on the non-drive side).
-
Unscrew hexagon socket screws (914.02) from bearing cover (360.01) and take off bearing cover.
-
Loosen grub screw (904.06) and pull outboard thrower (507.04) off the shaft.
-
Unscrew hexagon socket screws (914.02) from bearing cover (360.01) and take off bearing cover.
-
Bend lockwasher tang out of bearing nut (920.17) and screw off bearing nut. Take off lockwasher (931.02) and oil ring (644.01). Push spacer sleeve (525...) off the shaft.
-
To dismantle the bearing bracket, remove dowelling (tapered pins, 560...) on bearing bracket. Screw in (tighten) hexagon nuts (920...) to break the tapered pins out of their seats. Loosen adjustment screws 901...) on the bearing bracket flange.
-
Screw off hexagon socket screws (914.05) of the bearing bracket fastening. Loosen and remove bearing bracket together with bearing. Press out antifriction bearing outer race with rolling elements.
-
Draw inboard thrower (507.01) off the shaft, the antifriction bearing inner race will be taken along as well. If required use suitable puller.
Removal Removal of shaft seal - drive sid e Single-acting mechanical seal: -
Loosen external parts of shaft seal (mechanical seal cover) from shaft seal housing (441.02) and remove them, draw shaft sleeve off the shaft (mechanical seal with rotating parts)
-
Loosen and remove shaft seal housing (441...) by removing removing the hexagon socket screws (914.01) from suction casing. Be careful: Remaining careful: Remaining medium will flow out.
Removal Removal o f sh aft seal and balance device device Single-acting mechanical seal: -
Loosen external parts of shaft seal (mechanical seal cover) from shaft seal housing (441.02) and remove them, draw shaft sleeve off the shaft (mechanical seal with rotating parts)
-
Unscrew hexagon socket screws (914.01) fastening shaft seal housing (441.02), loosen shaft seal housing and pull it off. Be careful: Remaining careful: Remaining medium will flow out.
-
Draw sleeve (520.01) off the shaft and remove split ring (501.01) from the shaft groove. Take off key (940.04).
-
Mount device and draw balance drum (603.01) and balance drum liner (605.01) off the shaft. See sketch 8.1-3. Take off keys (940.02). Sketch 8.1-3 Removal of balance drum and balance drum liner
4330/e8-1-01-003 Page 3
50
Dismantling Dismantling of the hydraulic pump part Mark the stage casings, diffusers and impellers with the stage number during dismantling, as they must be refitted in the same place. -
Remove nuts (920.01) from the tie bolts (905.01) and withdraw the tie bolts.
-
Loosen and remove the delivery casing (107...) by carefully tapping with a rubber hammer and levering between the release pins. Be careful: Remaining careful: Remaining medium will flow out.
-
Remove last diffuser (177.01) from delivery casing
-
Slide the impeller impeller (230...) off the shaft, remove key (940.01)
-
Loosen and remove stage casing (108...) together with diffuser (171...).Be (171...).Be careful: Remaining medium will flow out.
-
Slide next impeller impeller (230...) off the shaft, remove remove key (940.01)
-
Dismantle stage by stage in the same way. Support shaft adequately to prevent bending.
-
Withdraw carefully shaft with first stage impeller out of suction casing, slide impeller off the shaft and remove key.
-
Press diffusers (171...) out of the stage casings (108...)
-
If required (in case of wear, wear, see 7.5): The wear rings (502...) in the suction casing / stage casings and the interstage bushes (541...) in the diffusers can be replaced.
Af ter di sas sem bl y All pump parts should be cleaned and prepared for short term storage by applying a rust preventive to all machined surfaces which are not made of stainless steel. Recommended rust preventives are given under 3.2.3 part II. Protection of the interior of the pump. Handle the pump shaft with care and whereever possible store shaft by hanging vertically to maintain staightness. Inspect all parts for wear or damage, see ..
4330/e8-1-01-003 Page 4
51
8.2 8.2
Overhaul - Inspectio n of wearing parts
Carry out all checks with the greatest possible care. Examine all parts for wear and re-machine or replace as the case may be. Negligence leads to a premature failure of the pump.
Impellers Inspect impellers for wear for wear or damadge. Look for cavitation marks (pits) in the suction area, erosion of vanes and cracks in the ahroud. Smooth minor irregularities with a fine file or emery paper.
Wear Wear rin gs and c learances learances Inspect wear rings for grooves and uneven wear. Check impeller clearances. The minimum diametrical clearances between impeller and wear ring is given in the table below. Replace impeller and wear ring when pump performance drops below acceptable system standards or the maximum clearances have been reached or exceeded. The permissible clearance between impeller and stage casing/wear ring can be taken from the following table. REMARK: Each
clearance enlargement causes efficiency loss in pump.
Pump size
100-300
150-360
200-400
Material index
Min. clearance
0.4
0.45
cast iron or soft nitrided steel
(with new parts)
0.55
0.6
stainless steel
Max. clearance
0.8
0.9
cast iron or soft nitrided steel
(with worn parts)
1.1
1.2
stainless steel
* clearance in relation to diameter Measure the clearance between corresponding sets of rotating and stationary parts. Use several measurement locations, then calculate the clearance as described below. Largest casing wear ring ID – smallest impeller OD = diametrical clearance
Wear Wear rin g replacement Case wear rings: Remove setscrews and press stationary wear rings out of their seats. Suction casing: Insert a pulling tool or pry bar between wear ring and seat and apply pressure. Stage casings: Note that bushing is shouldered on one side. Use a suitable press. Installation: Be sure rings and seats are clean and free of burrs. Install rings, chamfered towards inside, with a press. Fit and secure setscrews by peeling. Inter stage bush: Remove inter stage bushes by removing setscrews and tapping them out of their seats. A press can be used. Inspect seat and remove any burrs. Assemble new bushing. Drill and tap for setscrews. Fit and secure setscrews by peeling.
4330/e7-5-01-009 Page 1
52
Balance drum / Balance drum l iner Check outer diameter on balance drum, inner diameter on balance drum liner for accuracy to size. Replace balance drum/balance drum liner as a unit when the maximum clearances given in the table have been reached or exceeded. Pump size
100-300
150-360
200-400
Material index
Max. permissible
0.4
0.6
cast iron or soft nitrided steel
clearance (worn parts)
0.5
0.7
stainless steel
*clearance in relation to diameter
Balancing It is recommended that impellers are individually balanced on a balancing machine. Dynamic balance to VDI 2060, ISO 1940, Q = < 2,5. The assembled rotor is not balanced as a unit, since the deflection of the rotor is different during balancing in air to the deflection under the influence of hydraulic axial and radial forces in the close clearances within the pump.
Shaft Handle the shaft with care and support it evenly to maintain straightness. Avoid bumping, hitting or springing the shaft. True running of the shaft: Support shaft at bearing area (use V-blocks or rollers) and check for concentricity (max. permissible run-out 0.025 mm). If the run-out is outside the permissible value replace the shaft.
Mechanical seal The front sides of the sealing rings (running faces) should show no sign of scoring. Renew stationary and rotating seal rings which are scored or crazed, as a unit, never replace only one ring. Check shaft sleeve for perfect surface quality, especially at the seat of the rotating unit; renew if necessary. As sembly: In case of re-assembly use new gaskets and O-ring seals. We recommend the use of new rotating and stationary seal rings. Assembly must be done very carefully and under conditions of extreme cleanliness. The seal parts must by no means be subjected to any pressure or shock (danger of break). Seal faces should not be lubricated with oil or grease as this may prevent introduction of the sealed fluid in operation, leading to overheating and failures. Remove protective films from new parts direct before assembly.
ATTENTION
An ti fr ict io n b eari ng s Rinse bearings in light oil. In case of major overhaul or damaged, replace it. In case of renewed taper roller bearings: Use only paired bearings with reinforced intermediate rin g (without groove on the outside diameter) market by SKF through addition 03 to the bearing design number on the original packing. Never replace only one bearing of a unit. The bearing design number is given in the pump parts list.
ATTENTION
4330/e7-5-01-009 Page 2
53
Rotor concentricity check (shaft with rotating parts) Concentricity should be checked with the shaft in unloaded and loaded condition. Assemble the complete rotor. Instead of the last impeller insert a thread sleeve with SKF hydraulic nut HMV screwed on and a spacer sleeve according to sketch. The additional parts required can be supplied by the manufacturer (upon request).
Do not fully tighten the hydraulic nut. Support shaft at bearing area (use V-blocks or rollers). Make run out check in unloaded condition . The measuring points are: diameter of impeller clearances, the extension of the hub on the rear of the impellers, the shaft (protection) sleeves, balance drum and the coupling shaft end (see sketch). The max. permissible run out is given in the following table. Operating sp eed max. permissib le runout
3000
1
/min
0.04
1
1
> 3000 to 5000 /min
> 5000 /min
0.03
0.02
Hydraulic nut
If the run out test has been satisfactory, the same check is carried out with the loaded rotor . Connect SKF hand lever oil pump to the hydraulic nut (fill oil reservoir) and by manual operation of the pump, axially load the parts rotating with the shaft. Oil pressure required see table hydraulic nut . High pressure hydraulic equipment can be dangerous if misused. Use heavy gloves and eye protection. Make sure that the high pressure pump and high pressure pipes are not damaged. Use all equipment strictly in accordance with the instructions of the equipment manufacturer. When mounting, make sure that there is no leaking of oil at the connections. Jets of liquid escaping from high pressure equipment have sufficient power to penetrate the skin, which can cause blood poisoning. In case of such an accident, immediate medical attention must be sought. With rotor in loaded condition Repeat runout check on the same spots. If the gauge indicates an inadmissible runout all surfaces which are at right angles to the axis of the shaft and which are used to absorb or transmit axial forces, such as shaft shoulder, impeller hubs, balance drum and sleeves have to be checked for squareness. The max. permissible variance in the vicinity of the shaft outer diameter (shaft shoulders, hubs, sleeves etc.) should not be more than 0,01 mm. If this value is exceeded, re-machine: e.g. turn on mandrel (without clamping) or grind with the minimum possible reduction in the hub and/or sleeve length. Repeat concentricity check as described above. Upon satisfactory completion of concentricity check, dismantle rotor. Mark impellers in sequence so that they can be refitted in the same order when assembling the pump. Remove the special components used for the concentricity and keep to use in future overhauls.
4330/e7-5-01-009 Page 3
54
Components of t he hydraulic cl amping device for tr ue running test of ro tor
Hydraulic cl amping nut for Pump si ze
Size
d
D
e
h
Oil pressure
Part 008 Drawing No.
Part 009 Drawing No.
100-300
19 A
M 95 x 2
162
43
5
360
4-061 420
4-088 974
150-360
24 A
M102 x 2
188
44
5
430
3-086 836
4-089 060
200-400
26 A
M130 x 2
198
44
5
420
3-086 835
4-089 058
000 001 002 003 004 005 006 007 008 009
Hydraulic clamping nut, make SKF type HMV Union K-GEV 8L - G ¼ Pipe 8 x 1,5 DIN 2391 130 long Union K-GEV 8L - G ¼ Reducing socket ¾ x ¼ Pump support SKF 101 352 3 Wika-pressure gauge 211.100.600 bar Oil pump SKF 226 400 Sleeve Sleeve
1.0718 1.0308 GBK 1.0718 1.0718
1.0503.05 1.0503.05
* The additional parts required for the concentricity check can be supplied by the manufacturer upon request.
4330/e8-2-01-009 page 4
55
8.3
OVERHAUL - ASSEMBLY OF THE PUMP
References Refer to specific drawings (section drawing(s), parts lists, installation plan). A pump should only be assembled by qualified specialists with suitable tools and by strictly observing the instructions. ATTENTION
All assembly works have to be carried out with the greatest possible care. Negligence leads to premature failure of the pump.
Preliminary wor k -
Clean pump parts
-
Prepare lubricants (e.g. oil, Molykote, Never Seez)
-
Only use glycerine or "Klüber PROBA 270" paste for O-ring seals
-
Always renew seal rings and gaskets Pay attention to possibly hazardous situations during assembly, i. e. take care of a firm stand, secure assembly parts against dropping, support or prop loose parts etc.
As sem bl y of th e hydr aul ic p um p par t (Refer to matchmarks during reassembly) Note wi th pump sizes: 100-300 from 7 stages; 150-360 and 200-400 from 6 stages: With pumps having a large number of stages, the pump casing must be adjusted to the deflection line of the shaft. In such cases the correction is obtained by obliquely turning one or more of the stage casings. The oblique stage casing carries the mark “OBEN" and the number of the stage in which it must be mounted (counting from the suction end). See sketch 8.3-1. oben
Sketch 8.3-1 If the pump is assembled horizontally, the stage casings should not be supported underneath before the tie bolts are tightened, so that the stage casings can be “suspended". -
Clean shaft, impeller bores and coat the contact surfaces slightly with lubricant.
-
Insert key (940.01) for the first impeller, and push impeller (231...) onto shaft stop (210...)
-
Insert diffuser (171...) in the first stage casing (108...) and place O-ring seal (412.01) on the spigot of the stage casing.
-
Slide shaft with impeller into the stage casing from the drive side.
-
Insert key (940.01) and push on next impeller (230...) from the non-drive side.
-
Fit another pre-assembled stage casing (with diffuser and O-ring seal).
-
Assemble remaining stages in the same way.
-
Slide delivery casing (107...) with inserted last diffuser (177.01) and O-ring seal (412.12) on the spigot of the last stage casing (108...).
-
Place O-ring seal (412.01) on the spigot of the suction casing (106...) and mount suction casing.
4330/e7-6-01-002 Page 1
56
ATTENTION Adjust and support pump suction and discharge casing feet on a smooth steel plate. -
Fit tie bolts (905.01), discs (550.01) and nuts (920.01). Clamp the whole hydraulic assembly together evenly and crosswise. - see table 8.5 for tightening torques-
As sem bl y of th e bal ance dev ic e -
Insert key (940.02) for balance drum (603.01) and slide on balance drum with inserted O-ring seal (412.08).
-
Push balance drum liner (605.01) with O-ring seal (412.07) into delivery casing and allow the cylindrical dowel pin (561.02) preventing rotation to engage in the hole.
- Insert key (940.04) and split ring (501.01) into shaft and slide on sleeve (520.01).
Measurement of t heoretical axial positio n of rotor Measurement is not necessary, if the installation length of the pump parts have not changed through remachining during repair, but it is essential, if new parts (shaft, impellers, stage casings) have been fitted, otherwise continue wit h paragraph "Rotor centering procedure". In order to achieve the most favourable hydraulic efficiency of the pump, the impellers and diffusers must be placed in the optimum position to each other. For this purpose and in order to avoid lateral distortion of the rotor, the theoretical axial position of the rotor is to be measured and set. The construction tolerances make it possible to keep the correction of the axial rotor position within very low limits. Remark:
Mount all parts required for the measurement without o-ring seals.
-
Mount shaft seal housings on delivery casing (107...) and suction casing (106...) using hexagon socket screws (914.01). Note: Be sure venting bores of seal chambers are on top.
-
If present (see sectional drawing): Fit intermediate pieces (132...) on the shaft seal housings.
-
On both sides: Assemble bearing bracket lanterns (344.01) and bearing brackets (330...) and fasten with nuts evenly and crosswise.
-
Push rotor until stop in the direction of the non-drive side.
-
On the non- driv e side : Determine measurement „ A" (see sketch 8.3-2) from the support shoulder of the thrust bearing in the bearing bracket bore to the face of the shaft shoulder with depth gauge.
-
The (non-drive side) inboard thrower sleeve (507...) must be longer than the measurement" A" by the value " B" given in the following table Pump size Dimension
-
B =
100-300 6.5
150-360
± 0.1
± 0.1
7
200-400 8
Dimension in mm
± 0.1
New thrower sleeves are supplied with oversize, they must be machined to the calculated dimension. When repair work is done the nominal dimension can also be gained by applying supplementary discs.
ATTENTION
The max. permissible variance in the vincinity of the thrower sleeve shoulders is 0.01 mm.
4330/e7-6-01-002 Page 2
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Measurement of the axial position of rot or
Rotor pushed up to top in direction of non-drive side
A A + B
Sketch 8.3-2
-
On the drive-side: Check the length dimension of the thrower sleeve (507.01) while the rotor is moved to the non-drive side. To do so measure with depth gauge from the circlip in the bearing bracket (stop antifriction bearing outer race) to the front face of the shaft shoulder. The measuring result should correspond to the dimensions given in the following table. Pump size
100-300
measuring result
150-360 4
±1
200-400 5
Dimensions in mm
±1
Remark: Because of the big tolerance the spacer sleeve on the drive side has very rarely to be re-machined.
Rotor centering p rocedure The disassembly of the hydraulic pump part requires that the rotating element radial center position be determined and adjusted, otherwise continue with paragraph „Assembly of shaft seal non-drive side“ ATTENTION
Serious damage can be caused if the pump is started with off-center rotor
-
On the drive side: Loosen all adjusting screws and put bearing bracket in the lowest position possible.
-
Tighten fastening of bearing bracket and loosen them once again, so that the bearing bracket can be shifted by the adjusting screws (901.03) which are at the bearing bracket flange.
-
Adjust bearing bracket by the lateral adjusting screws. Measure between shaft and bearing bracket bore by means of an inside spring caliper until shaft is in the horizontal center. See sketch 8.3-3. Tighten and secure lateral adjustment screws in such a way as to fix the bearing bracket in horizontal position and allow vertical movement.
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Execute the lateral adjustment of the bearing bracket by turning the adjusting screws until shaft is set in horizontal center position of bearing bracket bore
Inside spring caliper
=
=
Adjusting screw
Adjusting screw
Sketch 8.3-3 Shaft
Bearing bracket
- Attach a measuring gauge vertically near the bearing (the measuring pin has to be positioned at right angle to the shaft) to ascertain at the bearing area by what dimension the shaft can be lifted. Divide the result by two and note. See sketch 8.3-4. ATTENTION
Do not bend the shaft! o
-
Mount roller bearing: Heat inner race of roller bearing (320.01) in oil bath up to 80 C and push onto shaft. Build in outer race with rollers into bearing bracket bore.
-
Fit measuring gauge again, screw in lower adjustment screw (901.03) until shaft is lifted by the dimension noted before. Fasten bearing bracket tightly. Observe measuring gauge, the shaft position must not change. Secure adjustment screws with nuts (920.03).
-
On the non-dri ve sid e: Measure shaft vertical movement in the same way as on the drive side. Fit another available roller bearing or an ancilliary bush with the corresponding dimensions instead of the taper roller bearing unit. Adjust bearing bracket in the same way as described for the drive side.
Check of f ree running state of the rotor ATTENTION
-
Due to manufacturing of the turbinepump parts within given tolerances the rotor theoretically should be in center position, i.e. could usally be turned by hand. To do so, attach lathe carrier at coupling shaft end and check free running.
Turn-on rotor and look for touching during running down.
Causese and measures in case of touchin g of the rotor 1. Center position of the rotor not correctly adjusted, adjust once again. 2. Tightening the screws in practice may, however, cause a different prestress in each screw by differing friction values in the thread and the nut support. Due to the differing prestress a deformation (bending) of the stage casing package, which is clamped together, may occur. This may cause a touching of the rotor parts at the stationary casing parts. With increasing stage number this will be more and more likely. If it is found that the rotor can only be turned under difficulty or not at all, the bending of the stage casing package needs correction by tightening the tie bolts with differing torques. As there is no proper way of predicting how the bending of the stage casing package will work out, the tie bolts to be tightened more strongly will have to be found by trying.
ATTENTION
Note: The torques given in the table 8.5 may be exceeded in these cases by max. 50 %. It may be necessary to adjust center position again! Af ter ch eck of fr ee run ning If check of free –running is satisfactory dowel bearing housings in new position. Existing taper pin holes can be reaimed to the next size taper pin or, if required, drill new holes. -
After measurement remove bearing brackets, bearings and bearing bracket lanterns on both sides again. Also remove thrower sleeves, dummy sleeves and shaft seal housings. Refer to 8.1.
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As sem bl y of th e sh aft seal ho us in gs -
Drive side: Insert key (940.04) for shaft sleeve.
-
Insert O-ring seal (412.02) in groove of the shaft seal housings (441...). Locate shaft seal housings on delivery casing (107...) and suction casing (106...) using hexagon socket screws (914.01).Note: Be sure venting bores of seal chambers are on top.
-
In case of shaft seal housing cooling: Place O-ring seal (412.02 or 412.03) on the spigot of the seal housing and O-ring seal (412.04) into the shaft seal housing groove. If present (see sectional drawing): Fit intermediate pieces (132...) on the shaft seal housings.
As sem bl y o f s haf t seal - non -dr iv e si de -
Mount rotating parts of the shaft seal on the shaft sleeve (523.01). Insert O-ring (412.10) in the groove of the shaft sleeve bore and push shaft sleeve onto shaft.
-
Build stationary elements of the mechanical seal into mechanical seal cover. Fit o-ring seal and slide on seal cover with the pre-assembled stationary parts of the shaft seal, but do not fasten yet.
As sem bl y of bear in g - no n-d riv e si de -
Lubricate the shaft and push inboard thrower (507.06) with nominal dimension into position on the shaft.
-
Mount bearing bracket lantern (344...). Lube threads and support surfaces of nuts (920.02) and tighten evenly and crosswise (tightening torque see 8.5).
-
Lift bearing bracket (330...) into position and screw on fasteners (914.05) finger tight. Insert taper pins (560...) through bearing bracket flange into bearing bracket lantern (344...). Support bearing bracket and seat taper pins, then properly tighten bearing bracket fasteners evenly and crosswise.
-
Assemble thrust bearing: Build in thrust ball bearing (320.02). Warm bearing in an oil bath to approx. o 80-100 C and push them up to shaft stop.
ATTENTION
In case of renewed thrust ball bearings:
Use only paired thrust ball bearings, never replace only one bearing of a unit. The bearing design number is given in the pump parts list.
-
Install spacer sleeve (525.05), screw on shaft nut (920.16 or 920.15 depending on model). Shaft nut (920.16): Screw on and tighten shaft nut (920.16). Secure shaft nut by tightening the adjusting screws. Shaft nut (920.15): Install spacer ring (551...), lock washer (931.01) and shaft nut (920.15). Apply lubricant to the contact faces of the lock washer and shaft nut. Tighten bearing nut and bend lock washer tang into one of the shaft nut slots.
ATTENTION -
Do not over tighten bearing nut.
Fit lubricating ring (644.01) in the spacer sleeve groove. Insert O-ring (412.05) into the bearing bracket groove. Install bearing cover and tighten bearing cover fasteners evenly and crosswise. Tightening torque see table 8.5. During tightening the rotor reaches the final axial position.
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As sem bl y of sh aft seal and bear ing - dri ve s ide -
Mount rotating parts of the shaft seal on the shaft sleeve (523.01). Insert O-ring (412.10) in the groove of the shaft sleeve bore and push shaft sleeve onto shaft.
-
Build stationary elements of the mechanical seal into mechanical seal cover. Fit o-ring seal and slide on seal cover with the pre-assembled stationary parts of the shaft seal, but do not fasten yet.
-
Lubricate the shaft and push inboard thrower (507.01) with nominal dimension into position on the shaft.
-
Mount bearing bracket lantern (344...). Lube threads and support surfaces of nuts (920.02) and tighten evenly and crosswise (tightening torque see 8.5).
-
Lift bearing bracket (330...) into position and screw on fasteners (914.05) finger tight. Insert taper pins (560...) through bearing bracket flange into bearing bracket lantern (344...). Support bearing bracket and seat taper pins, then properly tighten bearing bracket fasteners evenly and crosswise.
-
Ass emble radial bearing: Heat inner race of roller bearing (320.01) in an oil bath to approx. 80-100 C and push up to shaft stop. Build in anti-friction bearing (320.01) outer race with rolling elements into bearing bracket bore.
-
Install spacer sleeve (525.04) and lock washer (931...), screw on bearing nut (920...). Apply lubricant to the contact face of bearing nut and lock washer.
-
Tighten bearing nut and bend the lock washer tang into one of the bearing nut slots.
o
Do not over tighten bearing nut.
ATTENTION
Check and cor rect th e thrust bearin g axial clearance (end play) To allow the forming oil films between bearing parts and for heat expansion, it is necessary to provide a correct bearing end play. The bearing end play must be checked after every disassembly of the thrust ball bearings.
ATTENTION
-
Place clock gauge axially on the front of the shaft on the non-drive side; check axial clearance of the taper roller bearing unit by axially moving the rotor into its final positions. See sketch 8.3-4. Tap lightly on the bearing bracket (non-drive side) with a rubber hammer to straighten twisted rolling elements. Move rotor into its final axial positions, use device as shown. Tighten hexagonal nut (not too strongly), loosen, read clock gauge, loosen , tighten and read nominal end play.
1
2
Nominal end play 0.04 to 0.06 mm
Sketch 8.3-4 -
If there is no noticeable clearance the bearing elements may be twisted, turn rotor slowly in both directions and measure once again. If the measure axial clearance is smaller than 0.04 mm, the fault may be corrected by tightening the thrust bearing shaft nut (920.15) more strongly. Correct mistake.
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-
Remove device for bearing end play measurement. o
ATTENTION
If the taper roller bearing temperature after overhaul rises >90 C, as a first measure check bearing end play.
Final assembl y -
On the driv e sid e bearing bracket: Fit lubricating ring into the spacer sleeve groove. Insert O-ring (412.05) into the bearing bracket groove. Install bearing cover and tighten bearing cover fasteners evenly and crosswise. Tightening torque see table 8.5. Push outboard thrower (507.04) onto shaft, adjust gap between bearing cover and thrower to 1 mm and tighten setscrew (904...).
-
On the non-dri ve sid e bearing bracket: Push thrower (507.05) onto shaft, adjust gap between bearing cover and thrower to 1mm and tighten setscrew. Insert key (940.03) for fan (831.01) into shaft, slide on fan and place circlip (932.01) in shaft groove. Place fan cover (832.01) and fasten with cylindrical screws (900.06).
-
Mount coupling half: Insert key that drives the coupling into shaft. To assemble coupling half remove parts suspectible to heat (e.g. rubber buffer elements, sealing rings ...) and heat coupling half by homogeneous dry heating (e.g. oven, oil bath...) o to about 80 C. Push coupling half onto shaft using shaft centering thread (see sketch 8.3-5). When cooled down remount the disassembled parts. Couplings with bores up to 50 mm diameter may also be assembled in cold condition.
coupling half
ATTENTION -
The bearings must by no means be subjected to any pressure or shock.
pump shaft
nut
bar
stud
Sketch 8.3-5
Assemble pump onto baseplate. Couple driver, check alignment of coupling and tighten foot fasteners with torque wrench (see 5.2). Connect ancilliary equipment and instruments.
ATTENTION
Do not mix up connections. Carefully check piping system.
Electrical installations/connections for motors and controlling devices may only be carried out by qualified electricians. -
Fit coupling guard. Rinse bearing housing with light oil and fill with lubricating oil, see 7.3 and lubricant table T3.
ATTENTION
For recommissioning repeat all steps from paragraph 6.1.
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8.4 Tools A. Disassembly equipment for the balance piston and thrust bearing housing Part No. 1
Pump size
Part
40-180
50-220
1 Flange
80-260
200 x 25 x 165
Drawing No.
2-104 084 159
Article No. (tool set complete)
104 998 809 362
2
4 Stud (bearing hous. removal)
M 10 x 165
M 12 x 200
3
2 Stud (balance piston removal)
M 10 x 440
M 12 x 620
4
4 Disc
A 10.5
A 13
5
4 Nut
M 10
M 12
6
1 Hexagon screw
7
1 Ball
12 mm diameter
Sketch 8.4-1 Thrust bearing housing removal 1
2
M 20 x 1,5 (140 or 180 length)
6
7
4 5 Sketch 8.4-2 Balance drum (drum liner) removal 1
3
1 6
7
4 5
B. Rotor concentricity check (see also 8.2) Qty. 1
Qty. 1
Between balance drum and last stage impeller Disc Dimension in mm, inner dia. x outer dia. x thickness Pump size
40-180
50-220
80-260
Dimension
S 50x62x3
S 65x85x3.5
S 70x90x3.5
Instead of thrust bearing Sleeve Dimension in mm, inner dia. x outer dia. x length Pump size
40-180
50-220
80-260
Dimension
40x52x46
60x75x62
55x68x58
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8.5 Screw tightening torques l a e s g n i s a C
Tightening torques (Nm) part no.: 905.01 Working pressure (bar)
Pump size
g n i r O
< 80
> 80 to 120
> 120 to 150
40 – 180 50 – 220
710 1090
1030 1580
1260 1940
80 – 260 100 – 300
650 1000
940 1450
1160 1780
150 – 360 200 – 400
1550 2100
2250 3110
2770 3850
Tightening torques (Nm) for Pump size
bearing bracket fastening part no.: 920.02
40 – 180 50 – 220 80 – 260
bearing cover screws part no.: 914.02 / 03 20
105
30
205
100 – 300 150 – 360 200 – 400
Note: Tightening torques are only valid, if thread and support surface for nuts (respectively screw head supports) are lubricated.
Bolting sequence
A. Even loading Suggested torque values are recommended to produce properly stressed joints with a minimum probability of nuts, bolts or studs breaking or loosening. Avoid possible distortion by using correct tightening sequence during torque development.
➅
B. Thread lubes Lubricate threads and support surface for nuts with graphite and oil, molybdenum disulfide, or another anti-seize lubricant of comparable quality, except in instances where the lubricant is incompatible with fasteners application.
➁
➃
➆
➇
➂ ➀
➄
C. Torque development Tighten opposing fasteners in an alternating sequence when developing required torque. Lubricate and install fasteners finger-tight. Develop the required fastener torque in a minimum of three steps with a maximum of 33 % torque value on the initial pass.
nuts 920.02
nuts 920.02
tie bolt 905.01
➃
➁
➀
➂
screws 914.02
screws 914.03
Note: Refer also to 5.2 for tightening torques for pump feets
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64
➃
➀
➁
➂
➃ ➅ ➆ ➀ ➇ ➁ ➄ ➂
