ntt/ctt operating and maintenance instructions - imo pump · ntt/ctt 3 2 safety these operating...
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VM 460.0008 US/02.03
NTT/CTT
1
Operating and Maintenance Instructions
Volute–Casing Centrifugal Pumps Retainfor future
Series NTT and CTT use!
Order No.: Pump Ident. No.:
Machine No.: Pump Type:
Operating data, dimensions and other additional information can be found in the order–specific part of thedocumentation.
Contents
1. General
2. Safety
3. Transportation and Intermediate Storage
4. Description
5. Installation/Mounting
6. Start–up/Shutdown
7. Maintenance/Repair
8. Operating Faults, Causes and Remedial Action
9. Associated Documentation
Important note:This operating manual is to be supplementedby the order–related informations.
VM No.: 460.0008 US
Edition: 02.03 VS1
Ident No.: 550 102
These Operating and MaintenanceInstructions contain information fromthe pump manufacturer. They mayneed to be supplemented by instruc-tions of the operator company for itspersonnel. These instructions do nottake account of specific informationrelating to operation and maintenanceof the process plant into which thepump is integrated. Such informationcan only be given by the personsresponsible for construction and plan-ning of the system (system manufactur-er).Such specific instructions relatingto operation and maintenance of theprocess system into which thepump is integrated have priorityover the instructions of the pumpmanufacturer. The system manufac-turer must on principle observe thelimits of use!
Refer to the operating instructionsof the plant manufacturer!
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1 General
1.1 Pump designationThe exact designation can be found in the order–spe-cific documents (see data sheet).
1.2 Proper useInformation on proper use of the pumps is provided inthe technical data sheet.The pumped liquid must not contain any abrasive con-stituents nor corrode the pump materials.
1.3 Performance dataThe exact performance data can be taken from the or-der data sheet and/or acceptance test report.
1.4 WarrantyOur warranty for shortcomings in the supply is laiddown in our delivery conditions. No liability will be un-dertaken for damages caused by non–compliance withthe operating instructions and service conditions.If at any later date the operating conditions change (e.g.different fluid conveyed, speed, viscosity, temperatureor supply conditions), it must be checked by us fromcase to case and confirmed, if necessary, that the pumpis suited for those purposes. Where no special agree-ments were made, pumps supplied by us may, duringthe warranty period, only be opened or varied by us orour authorized contract service workshops; otherwiseour liability for any defects will cease.
1.5 TestingPrior to leaving our factory, all pumps are subjected toa leak test. Additional tests will only be performed on re-quest.
1.6 AvailabilityAs a matter of principle, we recommend stockingreplacement pumps and withdrawable units (hydraulicaction system) where the supplied pumps are adecisive factor in maintaining a production or deliveryprocess. In this way downtimes can be avoided, orreduced to a minimum.
1.7 Pressure limitThe sum of inlet pressure and maximum delivery pres-sure must not be greater than the permissible internalpump pressure (see data sheet).
NTT/CTT
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2 Safety
These operating instructions contain basic safetyinstructions for installation, operation andmaintenance. It is therefore essential that they are readby fitters and all specialist staff and customer personnelprior to installation and start–up. They must always bekept at hand at the place of installation.
The special safety instructions contained in the otherchapters must be observed in addition to the generalsafety instructions in this chapter.
2.1 Identification of safety instructions in theoperating manualThe safety instructions contained in these operatinginstructions which represent a danger to personnel ifnot complied with are specially marked by the general danger symbol:
Warning symbolas per DIN 4844–W9
Warning of danger from electric voltage is indicated asfollows:
Warning symbolas per DIN 4844–W8.
Instructions which are essential to avoid endangeringthe machine and its operation are marked by the word
ATTENTION
Instructions affixed directly to the machine such as
• Directional markers
• Signs for fluid connections
must always be observed and maintained in fullylegible condition at all times.
2.2 Personnel qualification and trainingThe operating, maintenance, inspection and mountingpersonnel must be appropriately qualified for the dutiesassigned to them. The scope of their responsibilities,competency and supervisory duties must be closelycontrolled by the customer. If the personnel do not havethe required knowledge, they must be trained andinstructed. If required, this may be provided by the
f t / li b h lf f th t Th
2.3 Dangers in the event of non–compliance withsafety instructionsFailure to comply with the safety instructions may resultin danger to persons, and place the environment andthe machine at risk. Non–compliance with the safetyinstructions will lead to the loss of any claims fordamages.Non–compliance may result in the following dangers:
• Failure of important functions of the plant
• Failure of specified methods for maintenance andservicing
• Danger to persons resulting from electrical,mechanical and chemical effects
• Danger to the environment resulting from leakage ofhazardous substances
2.4 Responsible working practicesThe safety instructions contained in these operatinginstructions, current national accident preventionregulations, as well as internal working, operating andsafety rules of the customer, must be observed.
2.5 Safety instructions for the user/operator
• Hot or cold machine parts representing a dangermust be protected against accidental contact onsite.
• Protection against accidental contact for movingparts (such as the coupling) must not be removedwhile the machine is in operation.
•
•
•
manufacturer/supplier on behalf of the customer. Thecustomer must additionally ensure that personnel fullyunderstand the content of the operating instructions.
When operating pump systems in a dust–ladenenvironment (e.g. milling, chipboard manufacture,bakeries), the surfaces of the pumps and motorsmust be cleaned at regular intervals, depending onlocal conditions, in order to maintain the coolingeffect and eliminate the possibility of spontaneouscombustion. Please also see explosion protectionregulations (ZH 1/10).
Leakage (e.g. from the shaft seal) of hazardoussubstances being handled, such as explosive, toxicor hot materials, must be discharged in such a waythat no danger to persons or the environment iscreated. Legal regulations must be observed.
Dangers from electrical energy must be eliminated.For details in this regard, please refer to localpower company regulations.
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2.6 Safety instructions for maintenance, inspectionand installationThe operating company must ensure that allmaintenance, inspection and installation tasks areperformed by authorized and qualified specialistpersonnel who have thoroughly studied the operatinginstructions.
2.7 Unauthorized conversion and production ofreplacement parts
2.8 Unacceptable modes of operationThe operational safety of the machine supplied is onlyensured when it is used in accordance with Section 1 ofthe operating instructions. The limit values given on thedata sheet must not be exceeded under anycircumstances.
3 Transportation and Intermediate Stor-age
3.1
3.2
Transport damage
Work on the machine is only to be carried out whenthe machine is at a standstill. The procedure for shut-ting down the machine described in the operatinginstructions must always be followed.Pumps or systems handling fluids which are detrimen-tal to health must be decontaminated. All safety andprotective devices must immediately be refitted andmade operational on completion of the work.The instructions under Section 6.1, “Preparation forstart–up”, must be observed before restarting.
Conversion or modification of the machines is onlypermissible after consultation with the manufacturer.Original replacement parts and accessories approvedby the manufacturer are required for safe operation. Ifother parts are used the manufacturer cannot be heldliable for the consequences.
TransportationThe pump or pump system is to be safely transportedto the place of installation, if required by means of lift-ing gear.
Crane and sling equipment must be adequatelydimensioned. Sling equipment must not besecured to the lifting eyes of the motor, except asadditional protection against overturning in theevent of nose–heaviness.
Transportation to and at the installation siteMake sure that the unit is transported safely and in astable position. Overturning due to nose–heavinessmust be prevented.
PackagingAttention must be paid to the figurative markings onthe packaging.The suction and discharge side and auxiliary connec-tions must always be closed during transportation andstorage.
The port coverings must only be removedimmediately before connecting thepipeline.
Check the pump for damage on receipt.Any damage detected must be reportedimmediately.
3.2
3.3 Preservation / Storage of centrifugal pumps
3.3.1
Under normal circumstances the pumpshave no special preservative.
At an additional charge we can, however, supplypumps and replacement parts ex factory with a preser-vative adequate to the planned storage period.
3.3.1.1 Outside preservationThe outside preservative should be applied by paintingor spraying with a spray gun.
3.3.1.2
3.3.1.3 Storage timesDepending on the required storage period and the sur-roundings, we recommend the use of preservativesfrom Valvoline GmbH, Hamburg.
Storage in a closed, dry and dust–free room
Storage time up to 6 months up to 12 months over 12 months a
Internal preserrvation Tectyl 511 M Tectyl 511 M Tectyl 506 EH
External preservation Tectyl 511 M Tectyl 511 M Tectyl 506 EH
Storage in the open–air
Storage time up to 6 months up to 12 months over 12 months
Internal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 542 Tectyl 506 EH Tectyl 506 EH
Storage in the open–air, tropical climate, aggressive industrial air orproximity to the sea
Storage time up to 6 months up to 12 months over 12 months c
Intermal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 506 EH Tectyl 506 EH Tectyl 506 EH
3.3.1.4
Preservatives can be removed with wax solvents, pe-troleum ether, diesel, petroleum or alkaline cleaners.However, the simplest method is to use a steam clean-er.Recommendation for Tectyl 506 EH: Allow petro-leum ether to act for 10 minutes before any further ac-tion.
Pumps that are used in the food or drinking water sectormust be dismantled and thoroughly cleaned prior to de-preservation.A suitable solvent that is compatible with the liquid to bepumped (drinking water/food) can be used as thecleaning agent, e.g. Spiritus, Ritzol 155 or suds with ahigh alkaline content. Steam cleaning is ideal.
After a prolonged storage period (morethan 6 months), all elastomers (O–rings,
shaft seals) must be checked for elasticity of shape.Embrittled elastomers must be replaced. EP rubberelastomers (EPDM) must be replaced.
3.3.2
3.3.3 Monitoring of preservationThe preservation must be checked at regular intervals.The preserved areas must be inspected every 6months and re–treated, if necessary.
We cannot accept any liability for defectsthat arise due to incorrect preservation
treatment.
3.3.3 Monitoring of preservationThe preservation must be checked at regular intervals.The preserved areas must be inspected every 6months and re–treated, if necessary.
We cannot accept any liability for defectsthat arise due to incorrect preservation
treatment.
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Points of preservation:All machined, unpainted surfaces (e.g. shaft ends,couplings, flange facings, valve and manometer con-nections).
Inside preservation(Not required for pumps made of stainless materials.)
PreservationIn the case of storage or prolonged outage, the pumpsmust be protected against corrosion. In those cases,an outside and inside preservation is to be provided.The durability of the protection against corrosion,which is limited in time, depends on the compositionof the preservative to be applied and the storageconditions.
a Internal and external preservation must be renewed after 48 months at the latest.b External preservation must be renewed after 18 months at the latest.
Internal preservation must be renewed after 48 months at the latest.c External preservation must be renewed after 12 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
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>
Note: The preservatives listed are to be regarded asa recommendation. Alternatively, technically equiva-lent products from other manufacturers can be used.When handling preservatives, follow the manufactur-ers recommendations and MSDS.
DepreservationPrior to operating the pump, the inside preservationmust be removed.Environmentally compatible disposal must beensured.
StorageDuring storage of the pump, the suction and outletflanges and all other supply and discharge openingsmust always be closed with dummy flanges or plugs.Storage should be in a dry, dust–free room. Duringstorage, the pump shaft should be rotated at leastonce a month.
Internal preservation is applied by painting, spraying,filling/dipping and subsequent draining. Finally, thesuction and outlet ports as well as all other supply anddischarge ports must be sealed with dummy flangesor plugs (plastic caps).
Points of preservation:All machined parts inside the pump (e.g. pump casinginside, bearing bracket, shafts, impellers anddiffusers).
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4 Description / Principle design of the pumpThe pictorial presentation may not correspond with the pump supplied.The actual design will be stated in the specific order documents.
Volute casing
Impeller
Bearing bracket
Shaft Shaft sealSafety stuffing box
Contact protection to EN 809 by coupling guard
Earthing connection to EN 809at the base plateGrounding connection to EN 809at the base plate
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5 Installation/Mounting
5.1 InstallationFor installation methods and locations, please see in-stallation drawing.
Other methods of installation are not permissiblewithout prior consultation with the manufacturer.
The safety regulations and tests in accordancewith DIN 4754 and VDI 3033 must be observedwhere pumps are installed in heat–transfer plants.
When installing the pump, please ensurethat the cooling air from the motor fan can
flow unimpeded over the bearing bracket to the casingcover.
5.1.1 Place of installation
Temperature:
relative air humidity:permanent max. 85 %temporary max. 100 %
Installation height:
For data differing from this, please consult the manu-facturer.
5.1.2
Heat insulationOnly the volute housing may be insulatedwith heat insulating material. In order to
enable optimum heat dissipation no other pump com-ponents may be insulated.
5.2 Foundation
min. –4 ˚Fmax. +104 ˚F
max. 3000 feet above sea level
Severe vibration in the vicinity of thepump unit can lead to bearing damage
and must therefore be avoided.
Protective devicesIn order to prevent injuries due to burns, at pumpingliquid temperatures higher than 140 ˚F protectivedevices in accordance with EN 809 must be providedon site.
5.2.1 Installation of pump assemblyTo insure adequate flow of liquid to pump’s inlet port,place pump near liquid source and preferably placepump centerline below liquid surface. Use short,straight inlet lines.
A dry, clean, well-lit and well-ventilated site should beselected for installing the pump assembly.
Sufficient open space should be provided aroundpump rotor and/or gear housing to permit routine visu-al inspection, on-site service and maintenance, andpump replacement. For installation and servicing oflarge pump units, ample overhead clearance shouldbe provided to allow for lifting device maneuvering.
5.2.2 Foundations and baseplates
Foundations and baseplates must be designed andinstalled so pump and driver alignment can be main-tained at all times. Be sure baseplates are level andrest on smooth flat surfaces. Small pumps may bemounted on baseplates or directly to existing floorsthat meet the criteria of foundations. Larger pumpsand/or drivers must be mounted to baseplates andfoundations. It is recommended that pumps and theirdrivers be mounted on common baseplates.
5.2.3 Mounting of foot mounted pumps and driversSome pumps are shipped on baseplates without driv-ers. For these units, install and tighten each couplinghalf on driver and pump shafts. Place driver on base-plate and set proper distance between shafts and cou-pling hubs (See Figure 5.2). Locate driver so pumpand driver shafts are in exial alignment.
Figure 5.3: Alignment of the coupling with dial gauges
Checking the coupling alignment
Adjusting the support footBefore aligning the coupling, all screws on the supportfoot (183...) must be loosened, so that the insert unitis stress–free. After aligning the coupling, screw thesupport foot (183...) down to the base plate. Themounting screw (901...) on the bearing bracket shouldstill be loose. Check that the bearing bracket is nottwisted during tightening.For this purpose, the fixingscrew (901...) must screw freely into the bearingbracket. If this is not possible, the seat of the supportfoot on the base plate must be corrected (e.g. by plac-ing shims underneath). Then tighten the mountingscrew (901...).
Checking the coupling alignment in case of hori-zontal setup on base plateA complete delivered pump assembly has been care-fully assembled at the factory. After proper installationand prior to start-up of the pump assembly, the align-ment of the coupling must be checked.The check can be made with a straight–edge and afeeler gauge, or with other suitable equipment (suchas a laser alignment device).
The measurements are taken in two planes, each off-set by 90, on the circumference of the coupling.
The gap between the two coupling halves must be thesame all round the circumference of the coupling. Thespecified gap is shown in the installation diagram.
The spacing between the straight–edge laid over bothcoupling halves and the respective shaft must be thesame all round the circumference.
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Figure 5.2: Alignment of the coupling with straight–edge and feeler gauge
For couplings with a spool piece (removable coup-lings) the alignment of the coupling can be checkedwith dial gauges.
Straight–edge
Feeler gauge
Note: The permissible axial and radial deviation,measured on the front face of the coupling and thecoupling circumference respectively, may be max.0.004”, but as far as possible should be kept below0.002”.
If a height, lateral or angle offset is detected betweenthe two coupling halves, the drive motor should berealigned such that the coupling halves are flush witheach other (level out with flat packing shims as neces-sary).
When the mounting bolts have been aligned andtighened the pump/drive motor unit must be able to bespun by hand freely.
Alignment errors on the coupling maylead to heavier wear of the coupling, the
anti–friction bearing and the shaft seal, and/or break-ing of the shaft.
Coupling alignment of special designed cou-plings (if present)Refer to the operating instructions of the couplingmanufacturer.
Assembly of pump and drive motorIf the unit is assembled at the place of use, the follow-ing work is to be performed:
1. Coat the pump and motor shaft ends with a fine filmof molybdenum disulfide (e.g. Molykote) and insertkeys.
2. Push on the coupling halves on the pump andmotor side with the aid of a pusher device until theshaft end is flush to the coupling hub.If no puller is available, heating the coupling halvesto approx. 212 ˚F (without rubber buffer) facilitatespushing.
The possibility of shock and stress on thepump and drive motor components mustbe eliminated.
3. Tighten the set screw on both coupling hubs.
4. When assembling the pump and motor, make surethe specified gap between the coupling halves ismaintained (see our illustration drawings).
5.3
5.3.1
5.3.2
5.3.3
5.4
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5. In the case of horizontally mounted pumpaggregates fixed on a base plate or directly on thefoundation, the coupling must be aligned asdescribed in Section 5.4.
6.
Fig. 5.4: Volute casing with guide bolt in the base plate
Space required for maintenance and repairThe pump must be accessible from allsides in order to be able to carry out
necessary visual inspections.Adequate space must be provided for maintenanceand repair work. It must also be ensured that allpipelines can be attached and removed withouthindrance.
Laying the pipelines
min. 5xDNs
min
. 5xD
Nd
Figure DN 1Recommendation for straight pipelinelength before and after the pump
In these areas, pipe fittings such as gatevalves, bends, compensators etc. shouldbe avoided wherever possible.
Shorter pipelines on the suction side arepossible, but may lead to a deterioration of
the hydraulic performance data. Shorter pipelines onthe discharge side are possible, but may lead to in-creased noise development.
Changes in cross–section and directionSudden changes in cross–section and direction, aswell as bends with a bend radius less than 1.5 times theinterior pipe width, must be avoided.
Supports and flange connectionsAll pipelines must be connected to thepump stress–free in accordance with
VDMA standard sheet 24277.The permissible pipeline forces must notbe exceeded in any operating status.
We therefore recommend on principle that a calculationof the pipeline forces is performed, which takes intoconsideration all operating status (e.g. cold/warm,empty/full, depressurised/pressurised, etc.).Pipeline supports must always be free sliding and mustnot rust in (check regularly).
How to assess a pipeline connectionTo conduct an assessment, the pipeline must be de-pressurised, completely drained and cooled. Thepumping liquid must be disposed of with respect for theenvironment.
Disconnect the pipeline from the pump at the con-necting flanges.
After disconnecting the connecting flanges, thepipeline must be freely movable in all directions inthe area of expected expansion.
Cleaning pipelines prior to attachmentPrior to assembly, all pipeline parts and valves must bethoroughly cleaned.
No impurities must reach the pump fromthe pipeline system (e.g. welding beads,
residues from preservatives, etc.).Flange gaskets must not protrude inwards. Blankingflanges, plugs, protective film and/or protective paint onflanges and seals must be removed completely.
Filters on suction side must be cleanedregularly. We recommend monitoring with
differential manometer and/or contact manometer.
5. In the case of horizontally mounted pump andmotor on a base plate or directly on the foundation,the coupling must be aligned as described in Section5.4.
6. Mount the coupling guard.According to accident prevention regulations, thepump must only be operated with a protection againstaccidental contact.
Note: When installing pumps with symmetrical feetwhich are supplied without base plate, make sure thatthe guide bolt at the volute casing is seated in a guidehole. The hole diameter must be provided according tothe representation below. The 3/16” distance must beobserved.
3 /16
”
Ø 2.756 +.008”
5.5
5.6
5.6.1
5.6.2
5.6.3
5.6.4
Nominal Pipe DiameterThe nominal diameters of the pipelines need not nec-essarily correspond to those of the inlet and outletflange, however, they must not be smaller. Differentnominal diameters of suction flanges and suctionpipelines are to be compensated by centric transitionpieces. Formation of air pockets is to be avoided.
Compensators must not generate anyunacceptable additional forces on the
pump connection flanges. Special care is needed incases where compensators are used, whose pres-surzed diameter is greater than the nominal width ofthe pump connection flanges.
Note: up to Ø 5.9” by handfrom Ø 5.9” with small lever
The flanges must lie parallel.
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Auxiliary connectionsThe positions of the auxiliary connections on the pumpare shown in the installation drawing. All auxiliarypipelines must be connected in accordance with theinstallation drawing, stress–free and sealed.
Safety and control devices
ThermometersThermometers must be provided to monitor the tem-perature of the delivery fluid.
Electrical connectionsThe power supply cables of the drive motor must beconnected by a trained electrician, according to themotor manufacturer’s circuit diagram. The valid VDEregulations, the regulations of the local electricity boardand the operating manual for the motor must becomplied with.Danger due to electrical power must be excluded andan EMERGENCY STOP switch in accordance with EN809 must be provided.
Refer 6.1...
Checking the pressure of the system with built–inpumpIf the whole system with built–in pump is to be sub-jected to a final pressure test, the test pressure mustnot be more than the maximum permissible internalpressure of the pump (see data sheet).
5.6.5
5.8
5.9
5.6.6
5.6.6.1
5.6.7
5.6.7.1
5.6.7.2
5.6.7.3
NPSH observationThe NPSH conditions of the system must be adaptedto the respective pump requirement (NPSHreq.). Anessential condition is fulfilled if the system NPSHvalue (NPSHavail.) is at least 11/2 feet above the pumpNPSH value (NPSHreq.). The NPSHreq. can be takenfrom the characteristic curves of the relevant pumps.
The applicable NPSH values in the char-acteristic curves are for water with 68˚F.
For other media and/or temperatures, the NPSHvalue may deviate from the characteristic curves.
Uncertainties in the determination ofNPSH conditions, particularly for media
other than water and/or other temperatures, must becompensated for by increased safety factors (pleaseconsult the manufacturer).
Inlet pipelineIn order to avoid the formation of air pockets, the inletpipeline must be layed raising to the pump.
Stop valve (inlet model)A stop valve is to be installed in the inlet pipeline. Itmust be fully open during operation (see figure DN 1).
Discharge pipeline
Stop valve in the discharge pipelineA valve should be installed in the discharge pipeline.
Check valve in the discharge pipelineThe pump must not run backwards. It is recommenedthat a check valve is installed between the dischargeflange and the stop valve.
BleedingIn the discharge pipeline, a bleed port should be pro-vided at the highest point and in front of the checkvalve.
Pressure GaugesWe recommend to provide suitable pressure gaugesin the inlet and discharge pipelines, and in the pres-surized auxiliary pipelines.
Safety devices in the inlet, delivery and auxiliarypipelinesSafety devices in the form of isolation valves must beinstalled in the pipelines, if not already provided, toallow the pipelines to be shut off and disconnectedduring maintenance and repair work.
The pump must not run dry, not evenfor checking the direction of rotation.
Control of drive motor direction of rotation
5.7.2
5.7.3
5.6.8
5.7
5.7.1
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6 Start–up/Shutdown
When starting up and shutting down the pump(s),general and special safety requirements for heatconducting equipment (e.g. from DIN 4754, VDI3033, etc.) must be observed as well as the appli-cable accident prevention regulations (e.g. UVV/VBG 64).Plant manufacturers and operators are respon-sible for informing personnel of safety require-ments, as well as for the implementation and con-tinued observation of the same.
6.1 Preparations for (initial) start–up
6.1.1
6.1.2 Filling and bleeding the bearing bracketDue to the sealing effect of the safety stuffing box, thebearing bracket must be separately filled with heattransfer oil.
6.1.3
6.2 Start–up
6.2.1 GeneralBefore starting, all filling and venting openings must becompletely closed.
6.2.2
6.2.4 DriveSwitch on the motor.Refer to the operating instructions of the drive motormanufacturer.
6.2.5
For bleeding and filling, the screw plugs of connec-tions V and FF are removed at connection FF, cleanheat transfer oil of the same quality as the liquidpumped is filled in until fluid emerges at connection V.In order to achieve a good flow it may be required toheat up the heat transfer oil prior to filling.
The connections must be resealed after filling andbleeding.
During bleeding of the pump and system, hazardousor environmentally harmful fluid and gas must be safe-ly collected and disposed of.
Control of drive motor direction of rotationThe direction of rotation of the motor must match thedirection of rotation arrow on the pump. To check thedirection of rotation, the motor can be switched onbriefly when the pump is full.
The pump must not run dry, not evenfor checking the direction of rotation.
In the case of pumps with a mechanical seal that isdependent on the direction of rotation, the motor mustal-ways be disconnected in order to check the direc-tion of rotation.If rotation is incorrect, the direction of rotation of thethree phase motor can be reversed by switching anytwo phases.
Checking the coupling alignmentPrior to starting and after the first run–up of the pumpto operating temperature, the coupling alignment andmounting of the supporting foot is to be checked.Readjust, if necessary (please refer to Section 5.4above). The pump shaft must be capable of beingrotated freely by hand.StartingTo avoid overloading the drive motor, the pump shouldbe run up only against a closed pressure isolationvalve during starting.The isolation valve in the inlet pipeline must be fullyopen.
6.2.3
Minimum rate of flowImmediately after reaching the operating speed, thedischarge isolator valve must be opened and thepump operated up to at least the minimum rate of flow(see data sheet)
Note for pumps in high temperature system:First, heat the system to 212 ˚F – 266 ˚F with thepump running. For these purposes, the isolation valveon the suction side must be completely opened. Runthe pump and system at this temperature until uni-formly warmed through and fully de-aerated. Thenheat up to operating temperature slowly.
The system manufacturers’ instructionsconcerning heat-up of the system have
priority over the above general recommendations.
Filling and bleeding the pump in the plantPrior to starting up, the pump must be bled in the sys-tem. For this, the system and the pump must be filledwith delivery fluid (see plant manufacturer’s operatinginstructions).During filling with delivery fluid, we recommend slow-ly rotating the pump shaft by hand to allow air pocketsto escape into the piping system.If the pump fails to build up pressure when started up(see pressure gauges), bleeding must be repeated.
6.2.6
Until the operating temperature has beenreached, it may be necessary to run the
pump at a reduced capacity. This will compensate forthe increased power consumption due to high viscosity.
6.2.7
It must be ensured that the pump housingis evenly heated. Differences in tempera-
ture between the top and bottom of the pump, as well assudden temperature changes, should be avoided.
6.2.8 Spare pump
6.3
•
• DriveSwitch off the motor. Make sure the pump runs downsmoothly and evenly.
•
6.4
Pumped liquid...
May solidify+
has a preservative effect aHear or drain pump Drain pump
May solidify+
does not have a preserva-tive effect
Hear or drain pump Drain and preserve pumpa
Does not solidify+
has a preservative effecta
– –
Does not solidify+
does not have a preserva-tive effect
– Drain and preserve pumpa
a See section 3.3
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Setting the pump power output valuesThe discharge isolation valve must be opened until therequired pump power output values are obtained (seedata sheet).
TemperatureIn order to prevent injuries due to burns, at pumpingliquid temperatures higher than 140˚F protectivedevices in accordance with EN 809 must be providedon site.
Temperature changes in the material of more than120˚F per minute are not permissible.
It is recommended a spare pump must always be keptready for operation. For these purposes, the isolationvalve on the inlet side must be completely open. Theisolation valve on the outlet side must be opened tosuch a degree that the pump, filled and bleded, can bebrought to operating temperature.
In systems in which impermissible temper-ature may arise due to failure of the oper-
ating pump, a standby pump of sufficient output mustbe provided.Two independent energy sources must be provided forthe operating and standby pumps.
Shutdown
It must be ensured that the pump does not run back-wards after switching off. Otherwise, the pump mayreach unacceptably high speeds, and shaft sealsdependent on the direction of rotation will be severelydamaged.
Discharge pipelineIf a check valve is installed in the dischargepipeline, the insolation valve can remain open.Without check valve, the isolation valve must beclosed.
Inlet lineClose isolation valve in inlet line.
Measures in the event of stoppage
Measures in the event ofbrief stoppage
Measures in the event ofprolonged stoppage
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7 Maintenance/Repair
7.1 Maintenance
• The instructions in Section 2, Safety, must beobserved in maintenance and repair work.
• Regular monitoring and maintenance of the pumpand the drive motor are essential for optimum ser-vice life and safety.
7.1.1 General monitoring
1. The pump must not run dry.
2.
3. The minimum delivery rate must always be main-tained (see Section 6.2..).
4. The drive motor must not be overloaded.
5.
6.
7. The pump unit must not experience or generate anyundue vibrations (e.g. as a result of incorrect align-ment). International standard ISO 10816 must be re-ferred to for assessment.
8. Changes to the normal operating data may indicatefaults. The causes must be established.
9. Installed standby pumps must be started up once aweek.
Note: In addition, the instructions for erection, oper-ation and servicing of heat transfer plants according toDIN 4754 and VDI 3033 are to be observed.
7.1.2 Maintenance of components
7.1.2.1 BearingThe nominal service life of the bearing is designed for aminimum of 2 years continuous operation, in accord-ance with DIN ISO 281. The actual usable life may belower, due to intermittent operation, high temperature,low viscosity, vibrations or the like.The running noises and the temperature in the bearingarea must be checked at regular intervals. We recom-mend monitoring bearings by means of shock pulsemeasurements. If damage to a bearing is detected, thebearing must be replaced.The bearing area can become very hot. Risk of burning if touched!
As a precautionary measure, we recommend thatthe ball bearings are replaced every 2 years.
The pump side medium–lubricated rolling bearing ismaintenance–free.
The drive–side rolling bearing is lubricated with specialgrease and is filled with grease at the factory.
• Bearing bracket size 360 and 470:Sealed rolling bearing with guard discs, providedwith a lifetime grease filling at the factory.
• Bearing bracket size 530 and 650:Open rolling bearing with Nilos rings and greasefilled at the factory. These bearings must be regu-larly relubricated. For the relubrication periods, please refer to the fol-lowing listing.
Speed Bearing bracket size
530 650
Lubrication period in operating hours
1450 11.400 10.500
1750 10.100 9.300
3. Unfavourable operating and ambient conditionssuch as dust, high air humidity, aggressive atmos-phere etc. may require even shorter lubricationperiods.
Fill with grease
• Fill hollow spaces between the rolling bodies up toapprox. 40% with grease.
Bearingbracket size
Rolling bearingAbbreviation
Grease quantityin grams
530650
6410 J C46413 J C4
• Scrape off excess grease (most suitably with yourfingers; do not use metal objects).
The pump must not run in cavitation mode.
The bearing temperature of rolling bearings mustnot exceed 248 ˚F.
The shaft seal must have no excessive leakage.
RPM
Notes:
1. At a maximum ambient temperature of 95 ˚F andmaximum admissible operating temperature, thetemperature at the drive–side rolling bearing isapprox. 158 ˚F. Higher ambient temperatures orbad ventilation may cause higher temperatures.
2. In case of temperatures over 158 ˚F, the lubricationperiod for each 59 ˚F temperature rise, must bereduced by one half!
35 or 1.2 oz.65 or 2.3 oz.
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Rolling bearing greases:For the lubrication of the drive–side bearing, the below–listed rolling bearing grease or an equivalent specialgrease with the following characteristics must be used.
Quality:The rolling bearing grease must be free from resin andacid and anti–corrosive.
Characteristics:Worked penetration 250–280 mm/10Dropping pointRange of temperatureapplication:
Manufacturer Brand
Klüber a ASONIC GHY 72
a Manufacturer: KLÜBER LUBRICATION MÜNCHEN KGGeisenhausenerstr. 781379 MünchenGermany
7.1.2.2
A defective shaft seal can cause uncontrolled dis-charge of pumping liquid. This constitutes a hazard to people (possibility ofspraying liquid) and to the environment!
At the site, it must be assured by the operator that theseepages drained through seepage drain LO are safelyand completely collected in a closed tank.
7.1.2.3 CouplingFollowing initial start–up, after first heating of the pumpto operating temperature and at regular intervals, thealignment of the coupling and the condition of the flex-ible elements in the coupling is to be checked (pleaserefer to Section 5.4 above).Note: Worn flexible elements are to be replaced.
7.1.2.4 DriveRefer to the operating instructions of the motormanufacturer.
7.2 Repair
GeneralThe system operator is responsible for ensuring that in-struction in safety is provided. The personnel must bemade aware of all hazards that can arise in connectionwith the pumped liquid or the plant.
a Hazardous substances are:
• Toxic substances• Health–endangering substances• Corrosive substances• Irritants• Explosive substances• Fire–inducing substances• Highly flammable, easily flammable and normally
flammable substances• Carcinogenic substances• Substances impairing fertility• Genetically distorting substances• Substances in other ways hazardous to humans
Pumps or units which pump hazardous substances orsubstances that are dangerous to the environmentmust be completely decontaminated.
Shaft sealThe built–in mechanical seal is maintenance–free.A maximum dripping rate of .35 oz. may occur duringoperation and is normal. If the dripping is heavier, theshaft seal must be replaced.
Mounting and repair workTrained Service engineers are available on request tosupervise repair work.For all repairs, it must be ensured that the pump isdepressurised, completely drained and cool. Themotor must be protected against unintended switchingon. We must refuse acceptance of repair work onpumps filled with fluid, for the protection of our staffand for environmental reasons. The expenditures fordisposal with respect to the environment are theresponsibility of the customer/operating company.
Hazardous substancesWhere repairs are to be carried out on pumps whichhave been operated with hazardous substances a
and/or environmentally harmful media, the cus-tomer/operator must inform its own personnel on site,or our personnel where repairs are returned to ourfactory or a service workshop, without being specifi-cally requested to do so.Together with the request for a Service engineer averification of system fluid, for example in the form ofa MSDS safety data sheet, must be submitted to us.
a Hazardous substances are:
• Toxic substances• Health–endangering substances• Corrosive substances• Irritants• Explosive substances• Fire–inducing substances• Highly flammable, easily flammable and normally
flammable substances• Carcinogenic substances• Substances impairing fertility• Genetically distorting substances• Substances in other ways hazardous to humans
Pumps or units which pump hazardous substances orsubstances that are dangerous to the environmentmust be completely decontaminated.
> 482 ˚F
-40 to 356 ˚F
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7.2.1
• Electrical danger must be eliminated! The motormust be secured against being switched on. Ifnecessary, the power supply cable must bedisconnected from the motor by an authorizedelectrician.
•
• Allow the pump housing to cool to ambienttemperature.
• Drain the fluid in flowable condition from the pump. Note: Use a collecting tank.
• The pump must be depressurized and drained.
• Hazardous substances and/or environmentallyharmful media must be drained off and collectedsuch that no danger to life and limb is created.Environmentally compatible disposal must beensured.
•
•
7.2.2
•
•
•
•
Disassembly of the centrifugal pumpBefore disassembly, the following work must be car-ried out:
Close all isolation valves in the inlet and dischargepipeline, and in the auxiliary pipelines.
• The pumps are produced as standard in process de-sign. This means that the insert unit can be dis-mounted without the need to remove the volutehousing and the pipes.
•
•
•
•
•
The pump must be disassembled by a qualifiedtechnician using the pertaining drawings.To prevent damage, it is especially important toensure that the components are disassembled con-centrically and that they are not tilted.
Disassembly instructions:
If a coupling with a spool piece is used, the motorcan remain on the base plate during this process.
The installed position of all components must beaccurately marked before disassembly.
Before assembling, check all parts forwear and distress and, as necessary,
replace with original replacement parts.Clean all parts before mounting. Always use new gas-kets.
The pump must be assembled by a qualifiedtechnician using the pertaining drawings. Theprescribed tightening torque must be observed.To prevent damage, it is especially important toensure that the components are installed concentri-cally and that they are not tilted.
Assembly instructions:
The markings applied during disassembly must beobserved. The components must be put back intheir original installed position.
When assembling, screws and nuts must be paint-ed with a suitable high–temperature anti seize com-pound (e.g. Molykote P37).
After installing the insert unit, the pump shaft mustbe aligned with the motor shaft.
After tightening the screws, it must be possible toturn the pump and drive freely by hand.
7.2.3 Tightening torque
Note: With poor and lightly greased surfaces, the va-lues must be increased by 10–15%, in order to reachthe required performance.
Pressure guage lines, pressure gauges and holdingdevices.
Remove auxiliary pipelines, if installed.
Remove coupling guard.
Thread QualityTightening
torque
902.1920.1 M 10 8.8 26 lbs-ft901.01 M 12 GA-T2 44 lbs-ft902.01 M 16 107 lbs-ft920 .01
901.02 M 12 8.8 44 lbs-ft902.02 M 16 GA-T2 107 lbs-ft
901.03M 10 8.8 26 lbs-ft901.14
901.13 M 12 8.8 23 lbs-ftM 16 107 lbs-ft
903.1903.2903.02 G 1/4 89 lbs-in903.06 G St 133 lbs-in903.07 G 22 lbs-ft903.18903.19
914.4 M 6 80 lbs-in
914.08 M 8 8.8 16 lbs-ftM 10 26 lbs-ft
M 20 x 1.5 83 lbs-ft922.2 M 24 x 1.5 1.7139 139 lbs-ft922.01 M 30 x 1.5 251 lbs-ft
M 36 x 1.5 516 lbs-ft
Part no.
Assembly of the centrifugal pump
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• Align coupling (please refer to Section 5.4 above).
• Attach protection against accidental contact andsupporting foot, if any.
• Attach manometer pipelines, manometer and hold-ing devices to the pump.
• Electrical danger must be eliminated! Power supplycables must only be connected by qualifiedelectricians. Pay attention to sense of rotation.
Start up pump as per instructions in Section 6.
7.3 Replacement partsThe application guidelines in accordance with DIN 24296 can be taken as a basis for spare parts stock hold-ing (see Section 7.3.2).
However, for reasons of operational safety, we recom-mend the stocking of complete insert units or sparepumps.Advantage: In the event of damage, a defective unitcan be replaced by a spare unit without great expendi-ture and in a very short space of time.
7.3.1 Ordering spare/replacement partsThe following details are required for handling ordersfor replacement and spare parts:
• a
• a
• a
•
•
•
a refer to name plate
7.3.2 Replacement parts for two–year continuous operation as per DIN 24 296
Part No. Part denomination Number of identical pumps (including standby pumps)
2 3 4 5 6 and 7 8 and 9 10 and more
Set/Replacement parts quantity
171.1 / 01 Diffuser (all two–stage pump sizes) 1 1 1 2 2 3 30%
210... a Shaft with distance washer 551.1 / 551.04distance washer 551.3 / 551.05impeller nut 922.2 / 922.01circlip 932.2 / 932.02circlip 932.7 / 932.07spring ring 930.1 / 936.01spring washer 930.2 / 934.01key 940.1 / 940.01key 940.2 / 940.02
1 1 2 2 2 3 30%
230.1 / 01 Impeller (all single–stage pump sizes) 1 1 1 2 2 3 30%
230.2 / 02230.3 / 03514.1 / 01904.5 / 05
Impeller first stage andImpeller second stage with aThreaded ring andHexagon socket with cup point
1 1 1 2 2 3 30%
321.1 / 01321.2 / 02
Groove ball bearingGroove ball bearing
11
11
22
22
33
44
50%50%
–
a
Cartridge–unit pump, consisting of:Bearing bracket, casing cover, shaft, groove ball bearing etc.
– – – – – 1 2
433.1 / 01 Mechanical seal, complete 2 3 4 5 6 7 90%
461.1 / 01 Stuffing box packing (set) 2 2 3 3 3 4 40%
diverse aGaskets for pump casing (set)Other gaskets (set) 4 6 8 8 9 12 150%
a Can be purchased as assembly group/sale group.
su orting foot, if any.
• Attach manometer pipelines, manometer and hold-ing devices to the pump.
• Electrical danger must be eliminated! Power supplycables must only be connected by qualifiedelectricians. Pay attention to sense of rotation.
Start up pump as per instructions in Section 6.
Following the installation of the centrifugal pump,the following operations are to be performed.
Attach coupling guard and supporting foot, if any.
●
●
●
●
Pump model numberPump serial numberYear of constructionPart numberPart descriptionQuantity
Part Description
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8.2 Causes and remedial action
Ref. no.: Cause Remedial action
1 Delivery head higher than nominal delivery headof pump.
a
2 Pump or pipelines not properly bled or filled.
3 Inlet pipeline or impeller blocked. Clean pipelines and impeller.
4 Air pockets forming in pipeline. Perhaps install a vent valve, or lay pipeline differently.
5 NPSHplant (inlet) too low. 1. Check fluid level in inlet tank.2. Open stop valve in inlet pipeline fully.3. Lay inlet pipeline differently if friction losses are too high.4. Check filter in inlet pipeline, if fitted.5. Check inlet flow conditions of pump.
6 Wrong direction of rotation of pump. Reverse polarity of any two phases on motor.
7 Rotation speed too low. a
8 Excessive wear on inner pump parts. Replace worn parts.
9 Density or viscosity of delivery medium does notcomply with pump design data.
Consult the factory in the event of faults due to non–compliancewith design data. a
10 Shaft sleeve damaged. Mount new shaft sleeve.
11 Delivery head lower than nominal delivery headof pump.
12 Rotation speed too high. Reduce rotation speed (turbine, frequenzy control, ...). a
13 Shaft seal damaged. Check shaft seal parts for wear and replace if necessary.
14 – –
15 – –
16 Re–align pump as described.
17 Pump twisted. Check pipelines for twists in connections.
8 Operating Faults, Causes and Remedial Action
8.1 Faults with reference number for cause and remedial actionThe table below is intended as a guide to identifying faults and their possible causes.
If faults occur which are not listed here, or which cannot be traced back to the listed causes, we recommend consulting thefactory, or one of our branch offices or sales offices.
The pump must be depressurized and drained when faults are being rectified.
1. Open isolation valve in discharge pipeline until operating point is reached.
2. Install impeller with larger diameter.3. Increase rotation speed (turbine, frequency control, ...).
Bleed and top off pump or pipelines.
Increase rotation speed (turbine, frequency control, ...)
1. Regulate operating point with isolation/control valve in dis-charge pipeline.
2. Turn off impeller in event of continuous overload.
Pump wrongly aligned.
Centrifugal pump faults Reference numbers for cause and remedial action
Delivery rate too low 1, 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Delivery head too low 2, 3, 4, 5, 6, 7, 8, 9, 21, 22
Power consumption of pump too high 9, 11, 12, 16, 17, 21, 22, 25
Delivery pressure too high 9, 12
Bearing temperature increased 16, 17, 18, 20, 25
Pump housing leaky 23
Heavy leakage of shaft seal 10, 13, 16, 17, 27
Pump not operating smoothly 1, 2, 3, 4, 5, 6, 8, 11, 16, 17, 24, 25, 26
Pump gets hot 2, 5, 26
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18 Excessive axial thrust. Clean relief bore holes in impeller.
19 – –
20 Specified coupling half gap not complied with. Set coupling half gap as per installation diagram.
21 Motor voltage incorrect. Use motor with correct voltage.
22 Motor runs only to two phases. 1. Check cable connection.2. Replace fuses.
23 Screws not tight. 1. Tighten screws.2. Replace gaskets.
24 1. Clean impeller.2. Re–balance impeller.
25 Groove ball bearing defective. Replace groove ball bearing.
26 Delivery rate below minimum. Increase delivery rate to minimum.
27 Pumped liquid corroding mechanical seal mate-rial.
Check pumped liquid (e.g.: incorrect temperature, concentra-tion, dosing of additives, etc.)
a Consult factory
Impeller out–of–balance.
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Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing boxShaft Seal Design: U5A
9 Associated Documentation
Design with intermediate ring
Sectional drawing NTTSizes at bearing bracket size 530 und 650
View X
Sectional drawing NTTSizes at bearing bracket size 360 und 470
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Sectional drawing NTTTwo–stage sizes at bearing bracket size 360
Denomination Part No.––––––––––––––––––––––––––––––––––––––Volute casing 102.01Stage casing 108.01Casing cover 161.01Casing cover 161.02Diffuser 171.01Supporting foot 183.01Shaft 210.01Shaft 210.02Impeller 230.01Impeller first stage 230.02Impeller second stage 230.03Groove ball bearing 321.01Groove ball bearing 321.02Bearing bracket 330.01Bearing cover 360.02Gasket 400.01Gasket 400.02Gasket 400.03Joint ring 411.02Joint ring 411.06Joint ring 411.07Joint ring 411.09Mechanical seal 433.01Stuffing box packing 461.01Intermediate ring 509.01Threaded ring 514.01Spacer sleeve 525.02Claming sleeve 531.01Washer 550.01
Denomination Part No.––––––––––––––––––––––––––––––––––––––Distance washer 551.01Distance washer 551.04Distance washer 551.05Rivet 565.01Rivet 565.02Pipe 710.01Hexagon screw 901.01Hexagon screw 901.02Hexagon screw 901.03Hexagon screw 901.13Stud bolt 902.01Screw plug 903.02Screw plug 903.06Screw plug 903.07Screw plug 903.09Grub screw 904.05Socket–head cap screw 914.08Nut 920.01Impeller nut 922.01Circlip 932.01Circlip 932.02Circlip 932.04Spring washer 934.01Spring ring 936.01Key 940.01Key 940.02Key 940.03Name plate 971.01Information plate 972.01
Connections–––––––––––––––––––––––FD DrainingFF FillingLO Leakage outletV Bleeding
Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing boxShaft Seal Design: U5A
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Sectional drawing CTTSizes at bearing bracket size 360 und 470
Sectional drawing CTTSizes at bearing bracket size 530 und 650
View Ysymmetrical feet
Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing boxShaft Seal Design: U5.1A
Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing boxShaft Seal Design: U5.1A
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Sectional drawing CTTTwo–stage sizes at bearing bracket size 360
Shaft seal: Uncooled, balanced mechanical seal with safety stuffing boxAbbreviation: U5.1A
Denomination Part No.––––––––––––––––––––––––––––––––––––––Volute casing 102.1Stage casing 108.1Casing cover 161.1Diffuser 171.1Supporting foot 183.1Shaft 210.1Impeller 230.1Impeller first stage 230.2Impeller second stage 230.3Groove ball bearing 321.1Groove ball bearing 321.2Bearing bracket 330.1Bearing cover 360.2Gasket 400.1Gasket 400.13Joint ring 411.1Joint ring 411.2Joint ring 411.18Joint ring 411.19Mechanical seal 433.1Stuffing box packing 461.1Threaded ring 514.1Washer 550.6Distance washer 551.1Distance washer 551.3
Denomination Part No.––––––––––––––––––––––––––––––––––––––Distance washer 551.4Spring dowel 560.2Rivet 565.1Rivet 565.2Pipe union 730.4Hexagon screw 901.13Hexagon screw 901.14Stud bolt 902.1Screw plug 903.1Screw plug 903.2Screw plug 903.18Screw plug 903.19Grub screw 904.5Socket–head cap screw 914.4Hexagon nut 920.1Impeller nut 922.2Spring ring 930.1Spring washer 930.2Circlip 932.2Circlip 932.6Circlip 932.7Key 940.1Key 940.2Name plate 970.1Information plate 970.2
Connections–––––––––––––––––––––––FD DrainingFF FillingLO Leakage outletPM2 Pressure measurementV Bleeding
Shaft seal: Uncooled, unbalanced mechanical seal with safety stuffing boxShaft Seal Design: U5.1A
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Order–specific Documentation
These operating instructions are supplemented by the following documents:
Acceptance of order No.
Data sheet No.
Installation drawing No.
Sectional drawing No.
Part list No.
COLFAX PUMP GROUP
A MEMBER OF THECOLFAX PUMP GROUP
Imo Pump1710 Airport RoadPO Box 5020Monroe, NC USA28111.5020
tel 704.289.6511fax 704.289.9273email [email protected] WWW.IMO-PUMP.COM
© 2003 Imo Pump All rights reserved.
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