OPERATING MANUAL

BA/e 1760 - API

Sulzer Pumps India Ltd. 9, MIDC, Thane-Belapur Road, Digha, Navi Mumbai, 400708. India. Tel. 091-22-55904321 Fax. 091-22-55904306

ZE/ZF

Doc

umen

t N

o. O

PM/Z

E-Z

F/0

01

Issu

e N

o. 1

1000/d0-1-00-000

Contents

1. GENERAL REMARKS

1.1 Guarantee 1.2 Delivery and purchase information 1.3 Pump Designation

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

3. TRANSPORT AND STORAGE 3.1 Transport / Lifting 3.2 Preservation and storage

4. DESCRIPTION 4.1 Description of the pump 4.2 Bearing bracket and lubrication

5. INSTALLATION OF THE PUMP 5.1 Mounting 5.2 Alignment of coupling 5.3 Suction and discharge pipework 5.4 Ancillary equipment Minimum flow device

6. OPERATION 6.1 Commission 6.2 Shut-down 6.3 Service control

7. MAINTENANCE AND OVERHAUL 7.1 Maintenance - Pump general 7.2 - Shaft seal 7.3 - Bearing lubrication 7.4 Overhaul - Dismantling of the pump 7.5 - Inspection of wearing parts 7.6 - Assembly of the pump

8. OPERATING FAULTS 8.1 Symptoms / Possible causes of faults / Remedies

0000/e1-0-00-000

1. GENERAL REMARKS

In the case of further questions, of spare part orders and other correspondence please mention always the SULZER Serial No. and pump type. Both can be gathered from the rating plate of the pump. Copyright remains property of SULZER.

1.1 Guarantee

Guarantee is assumed according to the contractual agreements.

1.2 Delivery and purchase information

As per drawings and data sheets. 1.3 Pump Designation

Process Pump ZE/ZF 100 - 2315 Pump Series Discharge branch DN (mm) Bearing Bracket Size Nominal Impeller Diameter (mm)

0000/e2-0-00-000 Page 1

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

- Non-observance of the safety regulations which might cause an endangering of people are marked

with the general sign for danger

Warnings of electrical voltage are marked specifically by

- Safety regulations the non-observation of which may cause danger for the machine and its operatability are marked by

- 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 da mages.

- 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 impac ts - Endangering of environment by leakage of dangerous materials

ATTENTION

0000/e2-0-00-000 Page 2

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. 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.

- 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.

E000/e3-0-00-001 Page 1

3. TRANSPORT AND STORAGE

3.1 Transport / Lifting 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.

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.

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. 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 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 3.1-2.

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

Never stay within the range of suspended loads.

Sling rope as market on

crate

Sketch 3.1-1

like this

Sketch 3.1-2

If required use traverse

E000/e3-0-00-001 Page 2

3.2 Preservation and storage

Preservation for despatch Standard When the pumps are shipped, smooth outside faces are sprayed with Tectyl 506 and pump internals with Mobilarma 524. Attention: this is not suitable as long-term preservation; 6 months are max. allowed time for storing. Seaworthy packing If the pump is despatched with PE-foil welding with moisture absorber (sea-worthy packing) the pump can be stored up to one year without any special maintenance if the packing is not damaged. Special packings On special request the pump can be packed in aluminium foil. In this case the preservation time amounts to 2 years.

If the seaworthy or other special package is removed, only the standard preservation is effective, i.e. if no further measures are taken, the max. storage period will be 6 months.

Intermediate storage Centrifugal pumps which are not installed and commissioned immediately after delivery can be stored for the period determined by the dispatch preservation.

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. 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:

In case of unfavourable ambient impacts such as moist atmosphere, greatly varying temperatures (day/night), acidy or alcaline ambience, danger of contamination (dirt etc.) the

connection flanges of the pumps have to be plugged airtight.

Longterm storage - preservation

In case a longterm storage is to be previsaged in the store of the client or on site or pumps affected by a longer shutdown of the plant or standby pumps are to be preserved, the following instructions have to be observed:

If pumps have been in service before, pump parts having been in contact with the pumped liquid must be cleaned and after drying be moistened with a preservative. For this purpose

the disassembly of the hydraulic part of the pump becomes necessary in most cases.

I. Protection of unencumbered, bright parts of the pump e.g. - pump shaft

- raised faces of flanges

- 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. This protective film can be removed by means of solvents or alkaline cleansing agents. We recommend rust preventatives -Cortec VCI 368 M from OKS speciality Lubricants (I) Pvt. Ltd.

Shell Ensis Fluid K from Shell Hydraulics.

- Rust Ban 397 from ESSO - Tectyl 506 from VALVOLINE

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

ATTENTION

ATTENTION

ATTENTION

ATTENTION

ATTENTION

E000/e3-0-00-001 Page 3

rustfree. The surface of the parts has to be cleaned carefully before the respective rust preventative is applied.

II. Protection of the interior of the pump e.g. - Pump casings - Stuffing box chambers - Bearing frames etc. For these parts, a liquid rust preventative on a mineral-oil basis having a viscosity of approx. 60 - 70 mm2/s should be used. We recommend the rust preventatives For gaskets in Perbunan (NBR), Viton (FPM), Teflon (PTFE): - Mobilarma 524 from MOBIL - MZ 110 from ESSO - Ensis motor oil 30 from SHELL - VCI 329 from OKS Speciality Lubricants - Rustlick 631 from ITW Signode India Ltd. Hyderabad. For gaskets in ethylene-propylene (EPDM): - Klber Syntheso D 220 -Silicone Grease or any vegetable oil

III. Proceeding in case of longterm preservation 1. Shaft seal

1.a Centrifugal pumps with soft packings 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. For packing material, we recommend: - synth. fibres, with PTFE impregnation (e.g. Chetra 1711 GS or Hecker 1820) The packing chamber is filled completely with the separate packing rings (stagger joints at 90 degree intervals). Note: Before commissioning, make sure that the preservation packing is removed and replaced by packing rings of the quality provided for operation.

1.b Centrifugal pumps with mechanical seals The complete mechanical seals remain within the stuffing box chamber. Pour rust preventative through the circulation and quench connections (see II.) and turn pump shaft manually several times while filling in the preventative.

2. 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 pump casing with rust preventative (see II.). 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. 3. Bearing frame

Also fill with rust preventative (see II) until lower edge of the shaft.

IV. Maintenance of the stored centrifugal pumps

At the parts which are filled with rust preventative (pump casing/stuffing box housing/bearing frame) the condensate should be drained every 6 months; rust preventative should be added, if required. To avoid corrosion damage at bearings, the pump rotor should manually be turned simultaneously, so that the preservation oil will be distributed over the running surfaces of the bearings.

According to manufacturers indications, the rust preventative has to be discharged and the spaces have to be refilled every 12 months*. 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. * If in the case of large pumps interiors are only sprayed preservation has to be repeated not later than after 6 months.

ATTENTION

ATTENTION

1760/e4-1-00-000 page 1 API 610

4. DESCRIPTION 4.1 Design of the pump

Pumps of the series ZE or ZF are horizontal, single stage, radially split, centerline mounted process pumps for heavy duty industrial and refinery service. They are designed as process pumps and correspond to the requirements of API 610 and ISO 5199, thereby guaranteeing the maintenance condition required by the process industry. The removable unit with bearing, shaft seal and impeller renders possible quick dismantling/assembly and herewith a short recondition time.

These pumps are suitable for clean and slightly polluted liquids. The permissible operating pressure and permissible operating temperature depend upon the material specification. See

1.4.8 for safety limit data for the pump supplied.

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.

Volute Case The radially split volute case is a machined casting with integral end suction and top discharge nozzles. A variety of alloys are optional to provide compatibility with pumpage. ANSI Class 300 or 600 raised face flanges are provided unless otherwise specified. Flanged drain is standard.

Gasket Fully confined compression gaskets between case, case cover and seal cover also between the impeller nut, impeller and shaft sleeve (dry shaft design).

Shaft Accurate machining provides precision fits and clearances for assem bly and operation. Machined shoulders provide positive location of mounted parts.

Impeller A closed single suction design impeller is used. The impeller is key-driven and locked with a self- securing capnut.

Wear Rings Replaceable case and impeller wear rings result in savings of spare part costs at repairs.

Mechanical Seal The inner chamber of the pump which is filled with liquid is sealed at the shaft by mechanical seals of different designs. See 7.2 or description of the seal manufacturer for further information.

The shaft seal housing is 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.

In case the pump must be heated the operating data acc. to 1.4.4 (sufficiently long preheating periods included) have to be observed, as with a too high viscosity of the fluid shaft sealing and

driver are endangered.

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 misalignment. A spacer is typically provided to allow pump disassembly without disturbing volute case or driver.

ATTENTION

ATTENTION

ATTENTION

ATTENTION

Sketch 4.1-1 Typical pump aggregate

1760/e4-1-00-000 page 2 API 610

4.2 Bearing bracket and lubrication (see sketch 4.2-1) A heavy-duty-bearing bracket with oil lubricated anti-friction bearings and automatic oil level regulation contains the pump shaft.

Anti-Friction Bearings The pump is equipped with a duplex angular contact thrust bearing and a single row roller radial or optional ball bearing arrangement. Pumps with high thrust loads are equipped with tapered roller bearing arrangement with fan cooling. See sectional drawing for bearing design delivered.

Constant Level Oiler An oiler is installed on the bearing bracket. 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 bracket oil level.

Fan A fan assembly can be provided according operating conditions to enhance air cooling of the bearing assembly.

Lubrication The bearing bracket is provided with splash oil lubrication. The oil level reaches to the antifriction bearing rolling elements. During operation they take along the lubricant and spread it on the race of the anti-friction bearing. The lube oil quantity is given under 1.4.2 and 7.3 .

Sketch 4.2-1 Bearing bracket and lubrication

fan (only in case of higher Temperatures)

radial bearing

sight glass

thrust bearing

oil level

shaft

oil ring constant level oiler

oil ring

0000/e5-1-00-000-API page 1

5. INSTALLATION OF THE PUMP

5.1 Mounting (see dimension drawing / installation plan)

General

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 plastic plugs 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 nonshrinking grout that is compatible with the highest and lowest temperatures to which it may be exposed. Use concrete from a concrete company with a final strength of 25 N/mm2 (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 baseplates should contain 300 to 350 kg cement per 1 m3 of concrete. The sand and gravel proportion for 1 m3 of finished concrete (1.2 m3 mixture) is as follows:

For grouting of the foundation bolts: 65% Fine sand grain size 1 - 5 mm

35% Coarse sand grain size 5 - 10 mm water as required

The use of so called fast cement with short setting time is possible.

For grouting (filling) of the baseplate: 40% Fine sand grain size 1 - 5 mm

60% Coarse sand grain size 5 - 15 mm

100 - 140 liters of water

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.

ATTENTION

0000/e5-1-00-000-API page 2

Installation of pump and driver

With separate baseplates for pump and driver first erect the pump, then align the driver.

- 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.

- Attach wire rope slings to the baseplate transport eyes (see 3.1 transport/lifting) and lift the baseplate with pump and driver. Insert foundation bolts into the holes in the baseplate and tighten the nuts a few turns.

- Lower the baseplate carefully into position on the foundation. The foundation bolts have to be lowered into the foundation holes.

Levelling

- 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).

Check levelling in the direction of the pump axis and also at right angles along the horizontal flange with a spirit (machinists) level. The flanges must be vertical on horizontal

branches. See sketch 5.1.1. Max. permissible variance 0.5 mm over 1m.

- 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 thicknesses. See sketch 5.1-2.

- Loosen adjusting screws and check levelling. If required correct levelling.

Grout in the foundation bolts - Before grouting wet the foundation holes. Fill foundation holes with concrete.

- After setting tighten the foundation bolts and check horizontal alignment again. If the position of the pump has changed, correct alignment.

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).

ATTENTION

ATTENTION

ATTENTION

concrete foundation

foundation bolt

sheet metal

shim shim

adjusting screw

disc

baseplate

5.1-2 Grouting foundation bolts

pump flange

shaft

spirit level

5.1-1 Levelling the unit

0000/e5-1-00-000-API page 3

Completion of grouting (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.

- 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.

- Finish grouting the baseplate in conformity with the corresponding installation plan. Fill the baseplate with thin-bodied 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

temperature of the foundation should not fall below 10oC. The optimum temperature for the setting process is 20oC +/-10 oC.

- 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 and check coupling alignment, see 5.2 (alignment report).

ATTENTION

ATTENTION

grout hole baseplate

chamfer strip

grout

foundation

5.1-3 Grouting of baseplate

1000/e5-2-00-000 page 1

5.2 ALIGNMENT OF COUPLING General

Before 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.

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.

Misalignment types There are three basic types of misalignments between the pump and driver shafts: Assembly The assembly of the coupling must be carried out in accordance with the coupling manufacturer's instruction. For mounting the coupling halves onto shaft see also 7.6.

Compensation of thermal growth Temperatures have a considerable influence and should therefore be considered during the alignment. The shaft centerline 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 growth

At pumps with feet bottom (not at axe level) and operating temperatures above 130 oC the thermal growth should be

considered.

Calculate the thermal growth Dh as follows:

1,2 x hP DtP Dh =

1000 X

100 = mm

Dh = Height difference in cold condition hP = Axe level pump DtP = Temperature difference between pump feet and environment in

oC

Acc. to experiences the temperature at pump feet amounts to 30% of temperature of liquid pumped Driver thermal growth

The thermal growth of the driver equipment must be obtained from manufacturer instructions.

Thermal growth varies with pumping temperature, load and ambient conditions. Final hot alignment must be done with equipment as close to operating conditions as possible.

Axial shaft distance The axial distance between the coupling halves must be observed. Please see installation drawing and hints on coupling assembly in the appendix.

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.

ATTENTION

ATTENTION

ATTENTION

ATTENTION

ATTENTION

1. Angular misalignment 2. Parallel offset 3. Axial distance Shafts with axes that Shaft with axes parallel Shaft with axes parallel intersect at a point but offset but wrong distance

Put calculated value here.

Shaft

Thermal growth

Thermal growth negligible

Shaft

1000/e5-2-00-000 page 2

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 the given torques (see pump foot tightening torques) and check alignment.

Alignment of non-spacer couplings With standard non-spacer flexible couplings, alignment can be checked with sufficient accuracy using a straight edge placed across the full width of the coupling halves. This check should be carried out at 90 intervals around the coupling periphery. The amount of parallel misalignment between the two coupling halves can be measured by inserting feeler gauges underneath the straight edge (see fig.).

Alignment of spacer couplings Every alignment check must be preceded by a run-out measurement at the coupling flanges. Record the results always in a log. All readings for radial and axial misalignment are determined in the gauge positions: top, bottom, right and left, i.e. every 90o, while both shafts are simultaneously turned. Alignment should be carried out with clock gauges in radial and axial direction (see fig.). The maximum admissible axial misalignment is 0,05 mm on diameter, although = 0,03 mm is preferable. The maximum admissible radial misalignment is 0,1 mm on diameter, although = 0,05 mm is preferable. 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.

Final alignment Final alignment check is done only after pump system is brought to normal operating temperature.

If misalignment above the admissible values given is found, the causes must be ascertained and eliminated. In most cases, the cause is unduly high forces and moments on the pump

branches, which arise through expansion of the adjacent pipework. See also 5.3.

Pump foot tightening torques

For the transport the tie bolts have to be tightened at the pump feet. After alignment of coupling, the fasteners pump-baseplate have to be tightened with the tightening torques shown in the table below.

Thread Tightening torque) Thread Tightening torque

Nominal diameter MA (Nm Nominal diameter MA (Nm)

M 16 60 M 36 900

M 20 120 M 42 1500

M 24 220 M 48 2400

M 27 350 M 56 3900

M 30 480 M 64 5900

M 33 680

ATTENTION

E000/e5-3-00-000

5.3 Suction and discharge pipework

General

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 in the suction pipework and 3 m/sec in the discharge pipework. It is also good engineering practice for the suction pipework to be at least one pipe size larger than the nominal bore of the suction flange. 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, especially with "emergency trip out", back-flow preventors have to built in.

Assembly

The pipework must be supported in an adequate manner to ensure that no bending moments or stresses caused by the weight of the pipework or thermal expansion are transmitted to the

pump flanges (install an expansion piece). The pipework flanges must be parallel to the pump flanges.

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.

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.

Where flanged joints are used ensure that the gasket is correctly centred so that the bore of the pipe is not restricted.

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.

Multi-pump installations should have separate sucton pipes to each pump. Excepted are duty and standby pumps which may have common suction pipework since only one pump operates at any time.

Cleaning the pipework

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.

Pressure test

The pipework should be pressure tested in accordance with the statutory regulations.

Pipe fittings

Fittings having the same nominal bore of the pipework should be used. If the pump branches have a smaller nominal bore than the fittings suitable taper pieces should be used. The shut-off

valve in the suction pipework should not be positioned immediately upstream of the pump suction branch to prevent turbulence entering the pump. The valve should be positioned with the handwheel horizontally or vertically downwards to prevent air pockets forming.

ATTENTION

ATTENTION

ATTENTION

ATTENTION

ATTENTION

0000/e5-4-00-000 page 1

5.4 ANCILLARY EQUIPMENT

General

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).

Do not mix up connections. After laying the pipes (and also after repairs), check the pipe runs.

The following instructions may be used as a guide insofar as they apply to the pump as delivered.

Ancillary pipework (see General Arrangement Drawings for applicable piping)

- 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.

Pressure measuring equipment

- The start-up and monitoring of the operating point of the pump is made easier with pressure gauges. See also 6.1 and 6.3. 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.

Bearing monitoring (impact impulse measurement, only possible with antifriction bearings)

- Advancing bearing damage can be recognised and monitored by means of impact impulse measurement. This requires a special measuring unit which is connected near the bearing through screw fittings (e.g. SKF connecting nipple No. 1649013 and SKF measuring unit MEPA 21 A).

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

ATTENTION

0000/e5-4-00-000 page 2

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 temperature smaller than 40 oC avoids deposits in the cooling water pipings.

- At pumps with high loaded bearings numeros 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.

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.

Electrical connections

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.

E000/e5-4-01-000

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.

Minimum flow device

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 impellers and casing wear rings leading to eventual breakdown of the pump. In case of mechanical seals a destruction of the seal parts has to be expected in addition. To avoid this there must always be a certain flow of liquid through the pump. 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) Automatic 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 leakoff non-return valve.

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 shut-down 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.

Never operate below pump minimum flow (see 1.4.1). Operation at minimum flow should be maintained for no longer than 2 hours in any 24 hours of operation.

ATTENTION

ATTENTION

ATTENTION

E000/e6-1-00-000 page 1

6. OPERATION 6.1 Commission

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 ancilliary 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 lubricant table T3. Check for correct oil level in sump.

c. Alignment: Check alignment of coupling. Be sure shaft rotates freely.

d. Shaft seal: Check mechanical seal (see 7.2). In case of double-acting mechanical seal fill of and vent sealing system.

e. Filling the pump - feeding operation Filling the pump - suction lift - Open shut-off valve in inlet line

- If existing (see installation plan) Open vent(not valid for self-venting casing)

- 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

- Turn pump rotor slowly by hand

- Mount coupling guards

- Fully open shut-off valve in suction pipe

- If existing (see installation plan) Open vent(not valid for self-venting casing)

- Shaft sealing chamber has to be vented (see also 5.4 Flushing and Sealing)

- Fill pump (suction pipe must have foot valve)

- Turn pump rotor slowly by hand

- As far as existing: Close vent when pumped medium flows without bubbles

- Mount safety guard

Before starting the pump, the suction piping, pump case and shaft seal chamber must be completely filled with liquid.

f. Check: Switch on the driver for a short time to check the direction of rotation and smooth running of the rotor (see direction of rotation arrow at the coupling).

An alteration of the rotational sense of the electric driver may only be carried out by a skilled electrician.

g. Minimum flow: If fitted, open and lock the valve in the minimum flow line (see also 5.4 - para. Leak-off Device).

Pump start-up and Operation (max. start-up frequency 12 starts/hour) a. If available, put ancillary equipment into operation (e.g.sealant pressure), open the valves in the ancillary pipework, vent pressure gauge (see also 5.4).

b. Start-up with unpressurised system

- Close shut-off valve in the discharge pipe (minimum flow must be guaranteed).

- Start driver

- Open discharge valve slowly, until the differential pressure drops to the value given on the data sheet.

c. Start-up with pressurised system (precondition is non-return valve in discharge pipe)

- Start driver with open discharge valve

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.

d. Observe ammeter reading. The full load amps given on the rating plate of the motor must not be exceeded.

ATTENTION

ATTENTION

E000/e6-1-00-000 page 2

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

- 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 deairing 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 materials of the pump are not suitable

- 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.

6.2 Shut-down (observe sequence)

a. If a non-return valve is fitted in the discharge pipe, the discharge valve can remain open, if shut-down 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.

b. Stop 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 c. If the pum p works on a suction lift and is not to be left ready for start-up, the suction valve should also be

closed.

d. If existing, close quench piping.

e. 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

g. If there is danger of frost or prolonged shut-down, empty and, if necessary, protect the pump casing, bearing housing and cooling chambers. See also 3.2.

The draining of the pump from toxic, explosive, hot or otherwise dangerous fluids must not lead to endangering of operator(s) and environment.

E000/e6-3-00-000

6.3 Service Control

Checking the duty point (design point) 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) =

density of liquid (kg/m3)

generated head (m) x density of liquid (kg/m3) generated pressure (bar) =

10 200

- The generated pressure must not fall below this value, 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.

Checking the capacity The capacity is determined from the pump performance curve and the generated head (m) as calculated above. - 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.

Capacity in (m 3/h)

Hea

d i

n (

m)

pump characteristic curve

E000/e7-1-00-000

7. MAINTENANCE AND OVERHAUL 7.1 Maintenance - Pump general

The pumpset should be checked for smooth, almost vibrationless running in service. To assess the vibrational behaviour the following regulations and guidelines could be used, e.g.

DIN / ISO standards 5199 ISO standard 10816 / 1 Horizontal pumps, which are fastened to the foundtion with anchors should not exceed a vibration speed of 4,5 mm/s. Vertical pumps, as well as horizontal pumps being mounted on buffer elements, should not exceed a vibration speed of 7,1 mm/s. When determining the measured values pump should operate at design point, see Chapter 1.4 (in case pump is operating at partial load or overload the vibration behaviour, f.e. by cavitation, will be influenced negatively). 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. In order to judge the conditions of the antifriction bearing a monitoring by means of shock pulse measurement is recommended. Pay attention to normal running noises. If any vibrations, unusual noises or faults are observed stop the pumpset at once. Ascertain the cause and rectify (see 8.1). During shut-down (according to operating requirements) check the alignment of the coupling (at least once a year). Re-align if necessary. Monitor ancillary equipment during operation: (if fitted) Gauges: pressure, temperature, ammeter at regular intervals Cooling: flow and temperature Flushing/Sealing : 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 7.4 to 7.6 for details on overhauling the pump. It is recommended to enter operating data and also data on lubrication, repairs etc. in an operating log. Standby pumps should be started at regular intervals to ensure their readiness for immediate service. During a prolonged shut-down the pump (and cooling system if fitted) should be drained and protected.

ATTENTION

0000/e7-2-01-001

7.2 MAINTENANCE - SHAFT SEAL Single-acting mechanical seal (for make, type and size see sectional drawing) General remarks 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

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 higher than working temperature

- no impurities in the slide ring region

If auxiliary facilities like

- flushing - blocking

- cooling

- 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. Maintenance

The maintenance of the mechanical seal is limited to the control of the leakage, of the temperature and, if fitted, to the auxiliary facilities.

A small leakage of the mechanical seal is normal. It is impossible, however, to make special 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. If so the damaged parts have to be replaced. Secondary seals (e.g. O-rings) have to be replaced during each assembly. Rotating and stationary seal rings must be replaced together.

ATTENTION

ATTENTION

0000/e7-2-01-002

7.2 MAINTENANCE - SHAFT SEAL Single-acting mechanical seal with throttling bush (for make, type and size see sectional drawing)

General remarks

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.

A non-sparking throttling bush with a small diameter clearance, installed in the mechanical seal cover, limits the leakage in the case of a mechanical seal failure to a minimum. At the same time the outlet of normal leakage along the shaft is avoided and a limited feed of quench agents becomes possible.

The quench outlet has always to be opened during operation. The quench inlet may be closed, if there is no quench feed.

Conditions

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 higher than working temperature

- no impurities in the slide ring region

If auxiliary facilities like - flushing

- blocking

- quench

- cooling - 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. Maintenance

The maintenance of the mechanical seal is limited to the control of the leakage, of the temperature and, if fitted, to the auxiliary facilities.

A small leakage of the mechanical seal is normal. It is impossible, however, to make special 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. If so the damaged parts have to be replaced. Secondary seals (e.g. O-rings) have to be replaced during each assembly. Rotating and stationary seal rings must be replaced together.

ATTENTION

ATTENTION

ATTENTION

0000/e7-2-02-001 back to back

7.2 MAINTENANCE - SHAFT SEAL Double-acting mechanical seal in back-to-back arrangement (for brand, type, size see sectional drawing) General remarks The shaft sealing consists of two mechanical seals (an internal and an external one) which are arranged back to back. The space between the two sealings has to be admitted with a suitable barrier medium. For the operating conditions of the pump the pressure of the barrier liquid should exceed the pressure in the pump at the internal shaft seal by at least 1-3 bar (max. 7-10 bar). Conditions

The barrier medium has to meet the following prerequisites:

- neutral towards the delivered fluid

- good lubricating properties - evaporation temperature considerably higher than operating temperature - no impurities In most cases the barrier medium necessary for the operation is provided by a external seal barrier system. The seal barrier system is connected with the shaft seal chamber by a forward and return line and serves for the following tasks: - providing the barrier medium quantity - circulation of barrier medium

- reduction of temperature (cooling) - monitoring and refilling of the liquid level in the barrier tank - monitoring of the barrier liquid pressure required (if required producing pressure on the barrier medium by

nitrogen addition)

In case there are any further facilities necessary for the operation of the mechanical seal such as - flushing of the mechanical seal on the product side

- cooling - heating etc. the information given under paragraph 1.4 and 5.4 has to be observed. 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. During the operation the permanent supply with barrier medium has to be observed respectively secured. At the seal barrier system a automatic pressure and level control should be installed.

A slight leakage of the mechanical seal is normal. With a certain barrier liquid pressure leakage occurs both towards the inside of the pump and towards the atmosphere side. More

precise information as to the quantity of the leakage of the mechanical seal cannot be furnished, however, as it depends on many different factors (e.g. size, material, fluid, temperature etc.). In case of a high loss of barrier medium, the mechanical seal rings or auxiliary seals are damaged. 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.

ATTENTION

ATTENTION

0000/e7-2-02-002 tandem

7.2 MAINTENANCE - SHAFT SEAL Double-acting mechanical seal in tandem arrangement (for brand, type, size see sectional drawing) General remarks The shaft sealing consists of two mechanical seals (an internal and an external one) pointing into the same direction (tandem). The space between the two sealings has to be admitted with a suitable barrier medium. In most cases a non-pressurised barrier is chosen.

Conditions

The barrier medium has to meet the following prerequisites:

- neutral towards the medium delivered - good lubricating properties

- evaporation temperature considerably higher than operating temperature - no impurities, contamination In most cases the barrier medium necessary for the operation is provided by a seal barrier system. The barrier system is connected with the shaft seal chamber by a forward and return line and serves for the following tasks: - providing the barrier medium quantity - circulation of barrier medium - reduction of temperature (cooling)

- venting of barrier liquid (to flare) - monitoring and refilling of the barrier liquid level during operation - monitoring of the barrier medium pressure (indicate seal damage or in case of pressurised barrier) In case there are any further facilities necessary for the operation of the mechanical seal such as - flushing of the mechanical seal on the product side - cooling

- heating etc. the information given under paragraph 1.4 and 5.4 has to be observed. Maintenance The maintenance of the mechanical seal can be lim ited 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 temperatures than the adjacent pump casing. In the case of cooling or heating the data mentioned in paragraph 1.4 have to be observed. During the operation the permanent supply with barrier medium has to be observed respectively secured. At the barrier system a pressure and level control should be installed.

A slight leakage of the mechanical seal is normal. The pumped medium leakage occurs into the barrier medium (to flare), the barrier medium leakage occurs towards the atmosphere

side. More precise information as to the quantity of the leakage of the mechanical seal cannot be furnished, however, as it depends on many different factors (e.g. size, material, fluid, temperature etc.) In case of a high loss of barrier medium (to be recognized by an increase or decrease of the liquid level in the barrier system), the seal rings or auxiliary seals are damaged. In this case defective parts have to be replaced. Auxiliary seals (such as 0-ring seals) have to be renewed during each assembly.

ATTENTION

ATTENTION

0000/e7-2-02-003

7.2 MAINTENANCE - SHAFT SEAL

Double-acting mechanical seal in tandem-arrangement (for make, type and size see sectional drawing) with pressurized barrier system The shaft seal consists of two mechanical seals (an internal and an external one) pointing into the same direction (tandem). The space between the two mechanical seals has to be admitted with a suitable barrier medium.

For the operating conditions of the pump the barrier medium pressure should exceed the pressure in the pump at the internal shaft seal by at least 1 bar.

Conditions:

The barrier medium has to meet the following prerequisites:

- neutral towards the medium delivered

- good lubricating properties

- evaporation temperature considerable higher than operating temperature

- no contamination

In most of the cases a supply of the barrier medium is not possible by an external source. The barrier fluid necessary for the operation is then provided by a tank. The barrier tank is connected with the shaft seal chamber by a forward and return line and serves for the following tasks: - absorption of barrier medium

- circulation of barrier medium

- reduction of temperature

- control of the liquid level in the barrier tank during operation

- control of the barrier medium pressure (if required producing pressure on the barrier medium by nitrogen addition)

In case there are any further facilities necessary for the operation of the mechanical seal such as

- flushing of the mechanical seal on the product side

- cooling

- heating etc.

the information given under paragraph 1.4 and 5.4 and in the pumps installation plan has to be observed.

Maintenance:

The maintenance of the mechanical seal can be limited to the control of the auxiliary facilities, leakage and temperature of the sealing cover. In the case of normal flushing by circulation the seal cover must not reach any higher temperatures than the adjacent pump casing.

During the operation the permanent supply with barrier medium has to be observed respectively secured. At the barrier tank a pressure control has to be installed.

A slight leakage of the mechanical seal is normal. With a certain barrier liquid pressure leakage occurs both towards the inside of the pump and towards the atmosphere side. More precise

information as to the quantity of the leakage of the mechanical seal cannot be furnished, however, as it depends on many different factors (e.g. size, material, fluid, temperature etc.). In the case of a high loss of medium delivered (to be recognized by an increase or decrease of the liquid level in the quench tank depending on whether the internal or external sealing is damaged), it must be reckoned with leaky seal ring pairs or leaky auxiliary seals. In this case defective parts have to be replaced. Auxiliary seals (such as O-rings) have to be renewed during each assembly. Sealing rings have always to be replaced in pairs.

ATTENTION

ATTENTION

0000/e7-2-00-000 page1

7.2 Maintenance - Shaft seal (Packed stuffing box) The stuffing box may be arranged in several ways depending on the operating conditions: (for details see the sectional drawing or separate shaft seal drawing)

Typical packing arrangements

Normal design

The whole packing chamber is filled with soft packing rings. The over-pressure at the shaft seal must be 0.1 - 0.2 bar. The liquid must have adequate lubricating properties and be absolutely clean. Design with lantern ring

A lantern ring is fitted in the packing chamber and is supplied with sealing liquid. Sealing will be necessary when over-pressure at the shaft seal is < 0.1 bar, when the liquid has bad lubricating properties or when it crystallizes or is contaminated. Quantity and pressure have to be adjustable by a regulating device in the inlet pipe. Sealing pressure: Has to exceed the pressure at the shaft seal by at least 2 bar. Quantity: about 0.015 m3/h. Leakage temperature (mixture of sealing liquid and pump leakage) max. 60C. Design with cooling of stuffing box gland

Cooling of stuffing box gland is necessary to prevent the formation of vapour in case of hot liquids (i.e. water over 110C) due to pressure relief at the shaft outlet. Quantity and pressure (about 0.05 m3/h at 0.2 bar) have to be adjustable by a regulating device in the inlet pipe. Temperature of mixture cooling water/leakage max. 40C. The cooling water must not however leak out as spray at the gap between stuffing box gland and shaft, it has to drain by the openings at the stuffing box gland. Pumps with liquid temperatures from 130C on are supplied with an additional cooling for the shaft seal housings.

Method of operation The function of the stuffing box is based on the packing passing on the pressure exerted on it (internal pressure of liquid) on all sides and thus filling the space between the stuffing box housing and shaft sleeve except for a small radial gap. Thus the leakage between the stationary and moving parts is greatly reduced. Good lubrication and heat removal are necessary for satisfactory functioning.

0000/e7-2-00-000 page2

Assembly of the packing (only on completely drained pump) The pumps are normally packed ready for despatch. If commissioning cannot take place within 12 weeks, the packing rings should be removed and repacked shortly before the start-up.

Before packing the shaft sleeve and stuffing box chamber should be cleaned and the shaft sleeve surface checked to see that it is satisfactory. Concentricity of the shaft sleeve should also be checked. Excentricity < 0,05 mm is permitted.

As preformed packing rings are recommended for repacking, a sufficient quantity should always be kept in stock. If you are manufacturing them yourselves from commercial packing cord, please adhere to the following dimensions:

Packing space height - mm

Commercial Cord mm inches

shape to h x b (mm)

8 7 5/16 8 x 6,1 = mould (moulds

10 9,7 3/8 10 x 9,5 can be

12.5 12 7/16 12,5 x 11,5 purchased

16 15 5/8 16 x 14 from SULZER)

Cut length = shaft sleeve diam. + 1,3 packing thickness x 3,14 Push the preformed packing rings one at a time into the packing chamber, using the gland, with the joints set at

90 to one another.

When fitting the lantern ring, insert one or two packing rings in front of the lantern ring, so that the sealing connection is clear. See drawing of shaft seal.

Tighten the gland evenly and squarely when the pump is empty and shut down. Check uniform gap between gland flange and stuffing box housing all the way round with gauges. Then loosen the gland and fit nuts hand-tight.

Monitoring

Slight leakage of the stuffing box packing is necessary during operation for lubrication and cooling. Leakage of approx. 1 drop per second up to a thin liquid stream of approx. 2 mm dia. is

regarded as normal at leakage temperature up to max. 60C.

To allow a check of the packing leakage on designs with lantern ring or stuffing box gland cooling it is necessary to block for a short time the inlet of the sealing respectively cooling liquid to these areas.

Note: In case of pumps with cooling of shaft seal housings: Never close the cooling liquid supply to the seal housings when pump works.

For pumps with suction pressure less than 10 bar: With greater leakage, tighten the gland evenly and squarely but not too tight. If leakage is too great despite retightening and is too hot, renew all packing rings.

For pumps with suction pressure over 10 bar:

Tightening the gland when the pump is running leads to shaft seal failure. Too much leakage requires repacking.

Each freshly packed stuffing box has a run-in time, during which it must be checked regularly. Higher leakage will reduce automatically after the run-in time. If ancillary services (e.g. flushing, cooling) are required to achieve the required operating conditions, the data under section 1.4 should be observed.

Packing material

The material for the packing rings depends on the kind of fluid and the operating data. For all industrial applications and the handling of food Graphite - PTFE (GFO-thread) has been wellproven. For orders give the exact designation from the parts list in the annex.

ATTENTION

ATTENTION

ATTENTION

ATTENTION

1700/e7-3-01-000

7.3 MAINTENANCE - LUBRICATION Anti-friction bearing with splash oil lubrication or ring lubrication 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 troublefree operation. The oil must not contain any foreign substances, acids or resins. Minimum requirements of suitable lubrication oils see DIN 51 524 (or alternatively DIN 51 517). Oil viscosity

Since, with anti-friction bearings, the self-heating of the bearing due to fulling plays an important role, and since, on the other hand an oil viscosity of at least 12 mm2/s at operating temperature of the bearing is required for a sufficient lubrication film, the oil viscosity has to be selected as follows:

Temperature C ISO kin.viscosity in mm/s ignit. point

Sump External ring Viscosity class 40 C 50 C *

>40 - 65 >60 - 85 VG 46 45 25 185 C

(* The figures for 50 C correspond to the previous system of lubricants.)

When during operation under extreme conditions (high ambience temperature, high bearing load etc.) a higher temperature is found at a certain measuring point, oil of the viscosity class ISO

VG 68 has to be used. The max. allowable values given in the table will then rise by 10 C. In case of bigger deviations contact the service. Besides we recommend to carry out the lubrication renewal under extreme bearing temperatures as described above in change intervals of half a year. Change intervals and oil quantity In case of first commissioning or of an overhaul, drain an filter all the oil after 10-15 hours of operation and refill it into the pump. If further pollution by foreign substances and water is low, change intervals of 12 months can be adhered to.

Bearing bracket size 0 1 2 3 4 5 6 7 8 9

Oil filling in litres 0.4 0.6 0.8 1.2 1.5 2.5 3.5 5.5 9.5 27

Bearing bracket size = first figure of the second number of the type designation (e.g. Z . 80 3 400 = bearing bracket size 3)

Check regularly the oil level in the bearing housings (oil sight glass). In the case of automatic constantlevel-oilers pay attention to refill the reservoir (oiler tank).

Max. allowable temperatures

Measuring Mode spot externally at bearing

housing near bearing at external bearing race in oil bath

continuous operation < 80 C < 90 C < 70 C

Alarm at > 90 C > 100 C > 80 C

switch off aggregate > 100 C > 110 C > 90 C

Check temperature at the measuring spots regularly.

Suitable lubricators of different brands see lubrication recommendation T 3 annex.

ATTENTION

ATTENTION

1700/e7-3-01-000

Recommended Lubricants T 3

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 between 0oC and 40oC.

The lubricants have been listed in alphabetical order which does not say anything about their quality

Supplier

Hydraulic oil according DIN 51 524 (DIN 51 517)

ISO VG 46 ISO VG 68

ADDINOL ADDINOL HLP 46 ADDINOL HLP 68

AGIP AGIP OTE 46 AGIP OTE 68

ARAL ARAL VITAM GF 46 ARAL VITAM GF 68

BP ENERGOL HLP 46 ENERGOL HLP 68

CASTROL CASTROL HYSPIN VG 46 CASTROL HYSPIN VG 68

CHEVRON EP HYDRAULIC Oil 46 EP HYDRAULIC Oil 68

DEA ETERNA LTD EP 46 ETERNA LTD EP 68

ELF ELF OLNA 46 ELF OLNA 68

ESSO ESSO NUTO H 46 ESSO NUTO H 68

MOBIL OIL MOBIL D.T.E. 25 MOBIL D.T.E. 26

SHELL SHELL TELLUS OEL 46 SHELL TELLUS OEL 68

TEXACO TEXACO RANDO 46 TEXACO RANDO 68

WINTERSHALL WIOLAN CA 46 WIOLAN CA 68

IOCL SERVO SYSTEM 46

HPCL ENKLO 46

CALTEX RANDO OIL 46

0000/e7-3-01-003

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.

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

refill here

casing

Oil bottle in working position

Oil level

gasket

Make sure that the glass bottle is tightly closed, if necessary replace gasket. Turn bottle handtight into threaded cover.

ATTENTION

ATTENTION

0000/e7-3-01-003

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. The cause may also lie in a too high an adjusted oil level.

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 (Adjustable Type) Loosen clamping screw and take off oil bottle of the constant level oiler. 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. Then fill the bottle with the same type oil and push it until stop onto the casing of the constant level oiler. Repeat this procedure until a minimum of 2/3 of the reservoir remains filled up, then fasten with clamping screw. Screw in and tighten filling plug. Check the supply in the bottle at times and refill, if necessary.

Constant level oiler working principle When the oil level within the bearing bracket 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 level adjustment The constant level oiler is adjusted at the factory prior to shipping, but should be checked before use. If it becomes necessary to adjust the oil level, remove bottle from oiler and lift the level adjuster from lower bottle. Raise or lower the cross arm as necessary, secure it with the lock, then replace adjuster and bottle. Check new level and readjust as required.

ATTENTION

1700/e7-4-00-000 page 1

7.4 Overhaul Dismantling of the pump (Brg. Bkt. - 0 to 5) When overhauling a pump it is advisable to procure all necessary spare parts (wearing parts) well beforehand to minimize 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: These pumps should only be disassembled by qualified specialis ts with suitable tools and by strictly observing the instructions. All assembly works have to be carried out with the greatest possible care. Negligence leads to premature failure of the pump. Preliminary work - Close the suction and discharge valves and secure them against unauthorized 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. A certificate attesting that it is absolutely safe must be included. 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 spacer

- Remove any instruments and ancillary pipes

- Disassemble pump and take it to assembly site - Drain off oil from bearing brackets

Dispose of used oil acc. to legal regulations. Never put it into the sewage system.

Dismantling of the assembly unit - rotor/shaft sealing/bearing (see sketch 7.4-1)

Pay attention to hazardous situations during dismantling, e.g. take care to stand firm, secure assembly parts against dropping, support or prop loose parts, hang on crane etc.

- If present: Loosen bearing bracket support foot (183.01) from baseplate. - Run a rope through eyebolt (910.01) of the bearing bracket and secure it through a crane. Note: The eyebolt

may not in the center of gravity.

- Remove hexagonal nuts (920.01) fastening the casing cover (161.01) (shaft seal casing) at the pump casing (102.01)

- Press assembly unit (consisting of bearing bracket, rotor and shaft sealing) out of its seat in the pump casing by use of jack screws and draw out completely (for heavier units use crane).

Pull

Jack screw

Eyebolt (910.01)

Nut (920.01)

Stud (902.01)

Casing (102.01)

Sketch 7.4-1

1700/e7-4-00-000 page 2

Disassembly of the assembly unit

Dismantling of impeller (see sketch 7.4-2) - Lock pump shaft and remove impeller nut (922.01). Note: The impeller

nut has a right-handed thread to tighten against rotation. In case the impeller nut is provided with an additional hexagon head screw (901.10), remove it beforehand (see pertaining section drawing).

- Draw off impeller (230.01), remove key (940.01). Note: Impeller is a slip fit, however, a puller may be required. If necessary, apply heat.

Dismantling of the shaft seal Disassembly of soft packing

- Remove the hexagonal nuts (920.03) tightening the gland (452...)

- Screw off bearing bracket fastening screws (920.02), disconnect casing cover (161.01) (shaft sealing casing) from bearing bracket (330...) (if necessary, hit cautiously with leaden sledge hammer against flange) and take off

- Remove rings of gland packing (461.01) from shaft sealing Chamber

- Push shaft protection sleeve (524.01) off the shaft, as the case may be, drive it off shaft with suitable auxiliary tool (flat bar or hammer)

- Take away gland (452...)

Dismantling of mecha nical seal standard type (see sketch 7.4-3)

- Loosen mechanical seal cover from casing cover (161.01) (shaft seal casing), remove all the fastening screws.

- Unscrew bearing bracket fastening nuts (920.02), disconnect casing cover (161.01) (shaft seal casing) from bearing bracket (330...) (if necessary, hit cautiously with leaden sledge hammer against flange) and take off.

- Push shaft sleeve including the rotating parts of the mechanical seal off the shaft (if necessary, drive off cautiously) and take away mechanical seal cover with stationary parts of the mechanical seal.

- For double mechanical seals (back-to-back or tandem type): Disassemble stationary parts of the