Heavy Duty Gear Pumps / AERN Series Pumps
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Transcript of Heavy Duty Gear Pumps / AERN Series Pumps
AERN Series
INDEX
Chapter Page No.
1 Introduction 1
2 Performance Characteristics 5
3 Operation 8
4 Shaft Sealing 16
5 Installation 17
6 Routine Maintenance Instructions 23
7 Trouble Shooting 24
8 Parts List 26
9 Assembly & Disassembly Instructions 27
10 Dimension Drawing 35
11 Warrantee & Test Certificate 36
Introduction1
1.1 GeneralThis instruction manual contains necessary information on the AERN series pumps having pump model of AERX, AERN & AERB and must be read carefully before installation, service and maintenance. The manual must be kept easily accessible to the operator.
ImportantThe pump must not be used for other purposes than recommended and quoted for without consulting the company or your local distributor.
Liquids not suitable for the pump can cause damages to the pump unit, with a risk of personal injury.
1.2 Reception, handling and storage1.2.1 ReceptionŸ Remove all packing materials immediately after delivery. Check the consignment for
damage Immediately on arrival and make sure that the name plate/type designation is in accordance with the Packing slip and your order.
Ÿ In case of damage and/or missing parts, report immediately to the carrier at once. Notify your supplier.
Ÿ All pumps have the serial number stamped on a name plate.
1
1
1.2.2 HandlingŸ Check the weight of the pump unit. All parts weigh-
ing more than 20 kg must be lifted using lifting slings and suitable lifting devices, e.g. overhead crane or industrial truck. See section 10 Weights.
Ÿ Never lift the pump unit with only two fastening points. Incorrect lift can cause personal injury and/or damage to the pump unit.
Ÿ Always use two or more lifting slings. Make sure they are secured in such away as to prevent them from slipping. The pump unit should be in a straight fashion.
Introduction
2
1
1.2.3 StorageŸ After receipt of Material and inspection if the pump is not to be installed
immediately the pump should be re-packed and placed in suitable places.
The following points should be noted:Ÿ Cover the pump with corrosion inhibiting treatment material.Ÿ Storage location free from, dust, moist and vibration free place. Ÿ Rotate the pump unit by hand weekly, to prevent jamming and damaged.
1.3 SafetyŸ The pump must not be used for other purposes than recommended and
quoted for without consulting the company or your local distributor.Always wear suitable safety clothing when handling the pump.
Ÿ Anchor the pump properly before start-up to avoid personal injury and/or damage to the pump unit.
Ÿ Check to see that the pump can be drained without injuring anyoneand without contaminating the environment or nearby equipment.
Introduction
3
1
Ÿ Make sure that all movable parts are properly covered to avoid personal injury.
Ÿ All electrical installation work must be carried out by electric personnel.Ÿ Improper installation can cause fatal injuries.Ÿ Dust, liquids and gases that can cause overheating, short circuits, corrosion
damage and fire must be kept away from motors and other exposed equipment.Ÿ If the pump handles liquids hazardous for person or environment, some sort of
container must be installed into which leakage can be led. All (possible) leakage should be collected to avoid contamination of the environment.
Ÿ If the surface temperature of the system or parts of the system exceeds 60°C, these areas must be marked with warning text reading "Hot surface" to avoid burns.
Introduction
4
2
2 Performance Characteristics2.1 capacityŸ Drop of capacity with increase in pressure & change of liquid
2.2 suction pressure The identification of suction pressure requirement is significant in any pump application.
Ÿ Its calculation helps to find out the suction lift of the pump, which enables to varify whether the pump will be able to self prime or not.
Ÿ The suction pressure or termed as NPSH ( Net Positive Suction Head ) can be calculated by following equation
NPSH = Atmospheric pressure + Static Head - Static Lift
viscosity
STATIC LIFT ATMOSPHERIC PRESSURE
STATIC HEAD
Performance Characteristics
5
22
2.3 Discharge pressure: Ÿ The discharge pressure shown in the delivery line is nothing but the overcoming
of system pressure created by the resistance of the pipeline and the shearing force of the liquid. Thus it can be said that a gear pump does not develop pressure by its own but work against the system pressure exerted on it.
2.4 Power Consumption:
Ÿ The power consumption of a rotary gear pump is mainly influenced by the differ-ential pressure exerted on it.
Ÿ Factors effecting on power consumption as follows:1. liquid viscosity2. Sp. gravity of liquid.3. Frictional loss.4. operating temperature
Performance Characteristics
6
2
2.5 Effect of Viscosity:Ÿ Viscosity is that property of any liquid which tends to
resist a shearing force. Ÿ The change in viscosity very much affects the perfor-
mance characteristics of the pump i.e. capacity, power consumption and speed.
Ÿ At a defined set pressure the capacity of a pump slightly reduces with decrease in viscosity. This may be due to increase in internal slippage.
Ÿ For a pump running at set speed for the desired capacity, the power consumption increases with increase of liquid viscosity and decreases with the decrease of viscosity.
Ÿ The above curves also show the effect of speed with reference to viscosity.
PO
WE
R C
ON
SU
PT
ION
SPEED
500
SSU
200
SSU
ACTUAL
THEORITICAL
PO
WE
R C
ON
SU
PT
ION
HYDRAULIC HP +VOLUMETRIC LOSSES
POWER CONSUPTION AN NO LOAD =
FRICTIONAL LOSSES
+
MECHANICAL LOSSES
OEFFERNTIAL PRESSURE
CA
PA
CIT
Y
THEORITICAL
500 SSU200 SSU
ACTUAL
OEFFERNTIAL PRESSURE
VOLUME TRIC LOSSES
CA
PA
CIT
Y
THEO
RIT
ICAL
500
SSU
200
SSU
SPEED
ACTUAL
Performance Characteristics
7
3
3.1 Genral Gears
Pump Casing
Seal Drive Shaft
Bearing
R.V. Cover
Relief Valve
Front Cover
Wear Plate
Operation
8
3
3.2 Operating Principal
The external gear pump uses two identical gears rotating against each other one gear is driven by a motor and it in turn drives the other gear. Each gear is supported by a shaft with bearings on both sides of the gear.
1. As the gears come out of mesh, they create expanding volume on the inlet side of the pump. Liquid flows into the cavity and is trapped by the gear teeth as they rotate.
2. Liquid travels around the interior of the casing in the pockets between the teeth and the casing it does not pass between the gears.
3. Finally, the meshing of the gears forces liquid through the outlet port under pressure.
Suction
Suction
Suction
Discharge
Discharge
Discharge
Operation
9
3
3.3 Safety Relief valve:3.3.1 Working PrincipleŸ
valve protecting the pump against overpressure. Ÿ It can be installed on the pump or in the installation.Ÿ This safety relief valve limits the differential pressure (Δp) between suction and
discharge, not the maximum pressure within the installation.For example, as media cannot escape when the discharge side of the pump is obstructed, an over-pressure may cause severe damage to the pump.
Ÿ The safety relief valve provides an escape path, rerouting the media back to the suction side when reaching a specified pressure level.
Ÿ The safety relief valve protects the pump against over-pressure only in one flow direction.
Ÿ The safety relief valve will not provide protection against over-pressure when the pump rotates in the opposite direction.
The positive displacement principle requires the installation of a safety relief
Operation
10
3
Ÿ
properly. Ÿ When the safety relief valve is not installed on the pump, other protections
against overpressure have to be provided.Ÿ If the pump rotates in the opposite direction, the safety relief valve or top
cover must be disassembled and turned around by 180°.
An open safety relief valve indicates that the installation is not functioning
Discharge Suction
Clockwise Direction Anti Clockwise Direction
DischargeSuction
Operation
11
3
3.3.2 Safety Relief valve adjustment:Ÿ
sure is performed at the factory.Ÿ To adjust the Safety Relief valve for oper-
ating pressure, proceed as follows :1. Open the hex cap.2. Tighten the ad. screw for increase
set operating pressure or loose the ad. Screw for reduce the pump operating
pressure.
▲ while increase of operating pressure, power consumption of pump must not exceed the motor rated power.
3. Tighten the hex cap. Make sure that air must leakge from hex cap & ad, screw.
Adjustment of the standard setting pres-
Operation
12
3
3.4 Check list for starting the pump:
3.4.1 Cleaning the pump
Ÿ There may be residual mineral oil inside the pump deriving from the pump testing and the initially lubricating of the bearing bushes.
Ÿ If the lubricating oil is not acceptable for the pumped liquid, the pump should be cleaned thoroughly.
3.4.2 Supply and discharge lineŸ Suction and discharge pipes are cleaned.Ÿ Suction and discharge pipes are checked for leaks.Ÿ Suction pipe is protected to entered foreign bodies.
Operation
13
3
3.4.3 CharacteristicsŸ
Ÿ Pump model see name plate, RPM, working pressure, effective power, working temperature, direction of rotation, NPSHr etc. as per application
3.4.4 Electrical installationŸ Electric motor rating as per application data sheetŸ Electrical installation is complete as per local regulationsŸ Motor voltage corresponds with mains voltage. Check terminal board.Ÿ Motor protection is adjusted properly.Ÿ Direction of motor rotation corresponds with direction of pump rotation.
The characteristics of the pump unit and safety relief valve to be checked.
Operation
14
3
3.4.5 Safety relief valveŸ
Ÿ Position of Safety relief valve according to direction of flow.Ÿ The set pressure of the safety relief valve is checked.
3.4.6 DriveŸ Alignment of pump, motor, gearbox etc. is checked
3.4.7 ProtectionŸ All guards and safety devices (coupling, rotating parts, excessive temperature)
are placed.
Safety relief valve (on pump or in piping) is installed
Operation
15
4
4. Shaft Seals:
Differnets type of sealing options areaviallable as under.1. Rubble oil seals2. Gland Packing3. Mechanical seal
17 6
4 3
5 2
Mech. Seal
Mech. Seal Part List
1
2
3
5
4
L-RingRotary Face
Stationary Face
Stationary Outer Ring
O"Ring
1
1
1
1
1
6 spring 1
7 Stationary Resting Part 1
Rubber Oil Seal & Gland Packing
Shaft Sealing
16
5
5. Installation:5.1 General:
Pump performance is also dependence on pump installation. This manual gives basic information which is to be observed during installation of the pump. It is important to read this manual by responsible person before installation.
5.2 Location & Foundation:Ÿ Locate the pump/pump unit as close as possible to the liquid source and if
possible below the liquid supply level. The better the suction conditions, the better the performance of the pump.
Ÿ The pump should always be located where it is accessible for inspection, main-tenance and repairing.
Ÿ Every pump should be provide a good foundation by any strong structure to hold the pump rigid and to absorb any strain or shock that may be encountered. If a separate foundation is provided, make it at least 4” wider and longer than base frame.
Ÿ When the unit is placed on the foundation, it should be leveled and checked for position against the piping layout and then fastened Owen.
Installation
17
5
5.3 Alignment:Ÿ
get the required speed.Ÿ The coupling may be direct drive or belt drive. However direct drive is
preferred over belt drive to reduce load on pump drive shaft and bearings.Ÿ During the operation shock load is produce due to pulsation. Therefore,
chose the coupling 1.5 time higher ration than normal constant load.Ÿ Pump and drive unit alignment must not more than as shown in fig.
For running the pump, it is required to couple pump with the drive unit to
Installation
0.2
00
mm
Parralel alignment
18
5
5.4 Piping:Ÿ
nection ports of the pump and shortest possible.Ÿ If the fluid to be pumped is high viscous, pressure
losses in the suction and discharge lines may increase considerably. Other piping components like valves, elbows, strainers and filters also cause pressure losses.
Ÿ Diameters, length of piping and other components should be selected in such a way that the pump will operate without causing mechanical damage to the pump/pump unit, taking into account the minimum required inlet pressure, the maximum allowable working pressure and the installed motor power.
Ÿ Check the tightness of the pipes after connection.
Use piping with an equal diameter than the con-
Strainer
PumpIsolation valve
Suction
Installation
19
5
5.4.1 Suction pipingŸ
level, the inclining pipe should rise upwards towards the pump without any air pockets.
Ÿ A too small diameter or a too long suction pipe, a too small or blocked strainer will increase pressure losses so that the NPSHa (NPSH available) becomes smaller than the NPSH (NPSH required).Cavitations will occur, causing noise and vibrations. Mechanical damage to pump and pump unit is not excluded.
Ÿ When a suction strainer or filter is installed pressure losses in the suction line must be checked constantly. Also check if the inlet pressure at the suction flange of the pump is still sufficiently high.
Liquids should enter the pump from a level higher than the pump
Installation
20
5
5.4.2 Isolating valvesŸ
Isolation can be done by installing valves in suction and discharge lines.Ÿ These valves must have a cylindrical passage of the same diameter of the piping.Ÿ When operating the pump, the valves must be opened completely. The
output must never be regulated by means of closing valves in suction or discharge pipes.It must be regulated by changing shaft speed or by re-routing the media over a by-pass back to the supply tank.
5.4.3 StrainerŸ Foreign particles can seriously damage the pump. Avoid the entry of these
particles by installing a strainer.Ÿ When selecting the strainer attention should be given to the size of the openings
so that pressure losses are minimized. The cross-sectional area of the strainer must be three times that of the suction pipe.
Ÿ Install the strainer in such a way that maintenance and cleaning are possible.Ÿ Make sure that the pressure drop in the strainer is calculated with the right
viscosity. Heat the strainer if necessary to reduce viscosity and pressure drop.
To allow proper maintenance it is necessary to be able to isolate the pump.
Installation
21
5
5.5 Electrical Installation.Ÿ
Ÿ Input voltage & frequency must be match with operating drive motor.Ÿ Install electrical overload safety device.
Make sure that electrical connection must be properly.
Installation
22
6
6 Routine Maintenance instructions:Ÿ
Ÿ Temperature of pump body should not exceed the operating temperature.Ÿ Check the leakage from suction and delivery line.Ÿ Check leakage from gland packing or shaft seal.Ÿ Check the air leakage from suction and relief valve.Ÿ Check the power consumption.Ÿ Check the temperature of the drive unit.Ÿ Check the alignment of the pump unit.Ÿ Check the axial and radial play of drive shaft
Check the nose of pump, Noise must not abnormal.
Routine Maintenance instructions
23
Suction lift too high. Lower pump or raise liquid level.
Fluid pumped not compatible with materials used
Use optional materials.
No barrier system to prevent flow passing.
Ensure discharge pipework higher than suction tank.
Pump allowed to run dry. Ensure system operation prevents this. Fit single or double flushed mechanical seals. Fit flushed packed gland.
Faulty motor. Check and replace motor bearings.
Pumping element missing Fit pumping element.
Relief valve leakage. Check pressure setting and re-adjust if necessary. Examine and clean sealing surfaces. Replace worn parts.
Relief valve chatter Check for wear on sealing surfaces etc. Replace if necessary.
Probable Causes Solutions
Incorrect direction of rotation Reverse motor.
Pump not Primed.
Insufficient NPSH available. (Cavitation)
Expel gas from suction line and pumping chamber and introduce fluid.
Increase suction line diameter. Increase suction head. Simlify suction line configuration and resuce length. Reduce pump speed.
Fluid vaporising in suction line. Increase suction line diameter. Increase suction head. Simplify suction line configuration and reduce length. Reduce pump speed.
Air entering suction line. Remake pipework joints.
Strainer or filter blocked. Service fittings.
Fluid viscosity above rated figure. Increase fluid temperature. Decrease pump speed. Check seal face viscosity limitations.
Fluid viscosity below rated figure. Decrease Fluid temperature. Increase pump speed.
Fluid temp. above rated figure. Cool the pump casing. Reduce fluid temperature. Check seal face and elastomer temp. limitations.
Fluid temp. below rated figure. Heat the pump casing. Increase fluid temperature.
Unexpected solids in fuid. Clean the system. Fit strainer to suction line.
Discharge pressure above ratedfigure
Check for obstructions i.e. closed valve. Service system and change to prevent problem recurring. Simplify dicharge line to decrease pressure.
Gland over-tightened Slacken and re-adjust gland packing.
Gland under-tightened adjust gland packing.
Se
izu
re
Pa
ck
ed
gla
nd
le
ak
ag
e
Me
ch
an
ica
l s
ea
l le
ak
ag
e
Problem
No
flo
w
Un
de
r c
ap
ac
ity
Irre
gu
lar
dis
ch
arg
e
Lo
w d
isc
ha
rge
pre
ss
ure
Pu
mp
wil
l n
ot
pri
me
Pri
me lo
st
aft
er
sta
rtin
g
Pu
mp
sta
lls w
hen
sta
rtin
g
Pu
mp
ov
erh
ea
ts
Mo
tor
ov
erh
ea
ts
Ex
ce
ss
ive
po
we
r a
bs
orb
ed
No
ise
an
d v
ibra
tio
n
Pu
mp
ele
me
nt
we
ar
Pump speed above rated figure. Decrease pump speed.
Pump speed below rated figure. Increase pump speed.
Pump casing strained by pipework.
Check alignment of pipes. Fit flexible pipes or expansion fittings. Support pipework.
Flexible coupling misaligned. Check alignment and adjust mountings accrdingly.
Insecure pump drive mountings. Fit lock washers to slack fasteners and re-tighten.
Shaft bearing wear or failure. Refer to pump maker for advice and replacement parts.
Insufficient gearcase lubrication. Refer to pump maker's instructions.
Metal to metal contact of pumping element.
Check rated and duty presures. Refer to pump maker.
Worn pumping element. Fit new components.
Trouble Shooting Trouble Shooting 7
24
10
11
12
13 14
15
16
17
18
19
20
21
22
23
24
25
26
2728
1
2
34
5
67
8
9
25
29
8 Parts List
AERN Pump with Needle Roller bearing as shaft BearingsAERX Pump with Needle Roller bearing as shaft Bearings & V-sealAERB Pump with Bush bearing as shaft Bearings
26
PARTS NO.
DESCRIPTIONS AERN PUMP
AERXPUMP
AERBPUMP
Drain oil plug
Bolt, gland cover
washer, gland cover
Gland cover
Shaft Seal
Bolt, Front cover
Washer, front cover
Dowel
Oil inlet plug
Shaft Bearing
V - seal
Wear Plate
Body Packing
Gears
Stator shaft
Rotor shaft
Bearing Sleeve
Snap Ring
Washer, Gear Shaft Assembly
Bolt, Gear Shaft assembly
Pump Casing
R. V. Cover
Hex Cap, Relief Valve
Adjustment screw
R. V. Plug
Spring Sheet
R. V. Spring
R. V. Piston
PARTS NO.
DESCRIPTIONS AERN PUMP
AERXPUMP
AERBPUMP
123456789
1011121314
151617181920212223242526272829 Front Cover
9
9.1 GeneralŸ
tioning, high repair costs and long-term inoperability.Ÿ Disassembly and assembly may only be carried out by trained personnel. Such
personnel should be familiar with the pump and follow the instructions below.Ÿ ANI Engineers is not liable for accidents and damage of the pump or pump unit
for faulty assembly.Ÿ Remove the pump from the operation.
9.2 Dissemble Instructions.
9.2.1 Remove gland coverŸ unscrew hex bolt no.2 & washerŸ Remove gland cover
Insufficient or wrong assembly and disassembly can lead to the pump malfunc-
24
Assembly & Disassembly Instructions
27
9
9.2.2 Remove Front coverŸ
Ÿ Open front coverŸ Remove body packingŸ Remove dowel if inside the front cover.Ÿ Remove V-seal if pump model AERXŸ Remove shaft bearing (Needle roller or bush )Ÿ Remove shaft seal from front cover,no.5
9.2.3 Remove R.V. cover assemblyŸ unscrew hex bolt no.6 & washerŸ Remove R.V. coverŸ Remove body packingŸ Remove dowel if inside the R.V. cover.Ÿ Remove V-seal if pump model AERXŸ Remove shaft bearing (Needle roller or bush )
unscrew hex bolt no.6 & washer
6
6 5
28
Assembly & Disassembly Instructions
9
9.2.4 Relief valve disassemblyŸ
find problem in relief valve operation.
Ÿ unscrew hex cap, no.23Ÿ unscrew Adjustment screwŸ Open relief valve plugŸ Remove spring sheetŸ Remove springŸ Remove piston.
Open relief valve assembly if
23
Assembly & Disassembly Instructions
29
9
9.2.5 Remove Gear shaft assemblyŸ
Ÿ Remove rotor and stator gear shaft assembly.
9.2.6 Gear shaft disassemblyŸ Unscrew bolts no. 20Ÿ Remove washers, no. 19Ÿ Remove gears & Bearing Sleeves from
shafts, use the plastic block to avoid shaft must not damage from press force.
Remove wear plates
SUPPORT
PRESS
Assembly & Disassembly Instructions
30
9
9.3 Assembly Instructions.9.3.1 Gear shaft assemblyŸ
hand & second is left hand in pair)Ÿ Insert bearing sleeve both side, replace if
damageŸ Insert washer and screw the bolt no. 20
9.3.2 Gear shaft assemblyŸ Assembled rotor & stator gear shaft
assembly in pump casing. Ÿ Assembled wear plate, replace wear
plates if wear out.Ÿ Replace gasket body packing with seal-
ant.
Insert Gears in the shafts (one gear is right
SUPPORT
PRESS
Assembly & Disassembly Instructions
31
9
9.3.3 Relief valve assemblyŸ
Ÿ Place spring in piston.Ÿ Place spring sheet on spring
Screw the relief valve plug.Ÿ Screw the adjustment screw as previously.Ÿ Screw the hex cap over the adjustments
screw.
9.3.4 Relief valve cover assemblyŸ Fit the bearing in Relief valve cover.
,replace bearing if damagedŸ Fit the V-seal in Relief valve cover if pump
model is AERX. (replace the V-seal if damaged)
Ÿ Fit the relief valve assembly with pump casing.
Ÿ Screw the bolt no. 6 with washer
Place piston in relief valve cover.
6
Assembly & Disassembly Instructions
32
9
9.3.5 Front cover assemblyŸ
bearing if damaged)Ÿ Fit the V-seal in front cover if pump
model is AERX. (replace the V-seal if damaged)
Ÿ Fit the front cover assembly with pump casing.
Ÿ Screw the bolt no. 6 with washer
9.3.6 Pump Rotation Check:Ÿ Checks the drive shaft rotates smoothly,
then fit all dowel and tighten the bolt no. 6.
Fit the bearing in front cover. (replace
6 5
Assembly & Disassembly Instructions
33
9
9.3.7 Gland cover Fitting:Ÿ
(replace the seal if damaged)Ÿ Push the gland cover in to the gland
box.Ÿ Screw the bolt no 2. With washer.
(each bolt should b tighten equally)
Fit the shaft seal in gland cover.
24
Assembly & Disassembly Instructions
34
10
AE-050-S-M-L
AE-100-S-M-L
AE-150-S-M-L
AE-200-S-L
AE-250-S-L
AE-300-S-L
AE-400-S-L
AE-500-S-L
AE-600-S-L
AE-601-S-L
239
271
318
359
419
461
554
615
690
749
150
160
180
200
220
240
280
295
340
360
110
130
145
165
190
220
255
280
318
357
80
90
105
110
130
160
180
200
220
240
100
110
130
150
160
220
270
300
350
380
91
100
119
133
163
166
189
215
215
230
80
90
100
112
132
160
180
200
225
250
69.0
74.0
80.0
89.5
100.0
131.0
145.0
160.0
178.0
200.0
12
12
14
14
15
20
22
25
26
28
08
10
10
12
15
18
18
19
20
22
4
4
4
4
4
4
4
4
4
4
89
108
127
152
178
190
229
254
279
279
16
16
16
19
19
19
19
22
22
22
60
79
98
121
140
152
190
216
241
241
22
25
25
40
40
53
53
60
70
70
30
30
40
50
55
60
65
85
95
100
11.5
15.0
21.0
24.0
27.0
32.0
37.0
47.0
52.0
57.0
4
5
6
8
8
10
10
14
16
16
13.0
17.0
23.5
27.0
30.0
35.0
40.0
50.5
58.0
61.0
SHAFT DIMENSIONS FLANGE DIMENSIONS MOUNTING DIMENSIONS OVERALL
DIMENTIONS Model
A F H2 B C E H H1 T D ø1No. OF HOLE
No. OF SIZE P.C.D. L L1 Dø P OD ø2 Kg.
Weight
8.0
14.0
22.5
28.0
43.0
59.0
82.0
150.0
175.0
190.0
35
Dimension Drawing
A
C E
H2
L
H
F
B
H1
DØ
2
T
4 Nos D Holes 1 Ø
L1
DØ Q
P
36
11
Desi
gn-P
rinte
d : K
eta
n P
ithva
98255 1
711
8