Centrifugal Pump, ACP series

Transcription

Erection Work, Operating and Maintenance Instructions
Machine:
Issued:
Checked:
Rev.0, Printed: 2010.08
Revision:
Checked:
The operating manual is protected by copyright. All usual rights reserved. It must not be wholly or
partly reproduced without authorization by Andritz AG. Contraventions shall entail damage claims and
may have penal consequences. All rights shall also be reserved for any patents granted, registration
of trade marks and technical modifications without prior notification.
© 2010 Andritz
TABLE OF CONTENTS
1
1.1
1.2
1.3
1.4
1.5
1.6
2
INTRODUCTION....................................................................................................... 6
Use .....................................................................................................................................................6
Standards and guidelines ...................................................................................................................6
How to use the manual ......................................................................................................................7
Warranty and guarantee ....................................................................................................................8
Manufacturer’s name and address ....................................................................................................9
Copyright ............................................................................................................................................9
SAFETY .................................................................................................................. 10
2.1
General safety regulations ...............................................................................................................10
2.2
Danger and warning signs ...............................................................................................................10
2.3
Designated use ................................................................................................................................ 11
2.4
General remarks on machine/plant safety ....................................................................................... 11
2.5
User’s obligations .............................................................................................................................12
2.6
General obligations of personnel .....................................................................................................14
2.7
Safety devices ..................................................................................................................................15
2.8
Personal protective apparel .............................................................................................................17
2.9
Safety at the machine installation site .............................................................................................18
2.10 Temperature .....................................................................................................................................18
2.11 Noise ................................................................................................................................................18
2.11.1
Noise levels (dB(A)) ............................................................................................................................... 19
2.12 Electrical equipment .........................................................................................................................20
2.13 Fluids (liquids, gases, vapor or smoke) ...........................................................................................20
2.14 Oils and greases and cleaning agents .............................................................................................21
2.15 Chemicals ........................................................................................................................................21
3
TECHNICAL DESCRIPTION .................................................................................. 23
3.1
General description ..........................................................................................................................23
3.1.1
Field of application ................................................................................................................................. 23
3.1.2
Design ..................................................................................................................................................... 24
3.2
Main components of the centrifugal pump .......................................................................................25
3.2.1
Centrifugal pump with base frame ......................................................................................................... 25
3.2.2
Centrifugal pump .................................................................................................................................... 26
3.2.3
Bearing support ...................................................................................................................................... 27
3.3
Type of seal ......................................................................................................................................29
3.3.1
Andritz cartridge mechanical seal - single .............................................................................................. 31
3.3.2
Andritz cartridge mechanical seal - double ............................................................................................ 32
3.3.3
Standard cartridge mechanical seal - single ............................................................................................ 34
3.3.4
Standard cartridge mechanical seal - double .......................................................................................... 36
3.3.5
Single standard mechanical seal ............................................................................................................. 38
3.3.6
Tandem standard mechanical seal........................................................... Error! Bookmark not defined.
3.3.7
Stuffing box packing............................................................................................................................... 40
3.4
Type specification ............................................................................................................................42
3.4.1
Applicable standards............................................................................................................................... 42
3.4.2
Model designation .................................................................................................................................. 42
3.5
Application limiting values ................................................................................................................43
3.6
Performance limits for bearing supports for different shaft material ................................................48
3.7
Technological description .................................................................................................................49
4
4.1
4.2
4.3
ERECTION AND TRANSPORT .............................................................................. 50
General ............................................................................................................................................50
Safety regulations ............................................................................................................................50
Haulage ............................................................................................................................................51
Page 3 of 117
4.4
Storage ............................................................................................................................................ 55
4.5
Installation ....................................................................................................................................... 56
4.5.1
Erection of the centrifugal pump ............................................................................................................ 57
4.5.2
Pipework................................................................................................................................................. 60
4.5.3
Aligning the coupling ............................................................................................................................. 61
4.6
Instruments ...................................................................................................................................... 62
4.7
Electrical equipment ........................................................................................................................ 63
4.8
Cold test .......................................................................................................................................... 64
5
5.1
5.2
5.3
5.4
5.5
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
7
START-UP .............................................................................................................. 66
General ............................................................................................................................................ 66
Safety regulations ............................................................................................................................ 66
Prerequisites for start-up ................................................................................................................. 67
Start-up ............................................................................................................................................ 69
Certificates....................................................................................................................................... 70
OPERATION ........................................................................................................... 71
General ............................................................................................................................................ 71
Control via DCS ............................................................................................................................... 72
Starting ............................................................................................................................................ 72
Checks after initial start-up .............................................................................................................. 73
Normal operation ............................................................................................................................. 74
Centrifugal pump requirements (delivery head and flow rate) ........................................................ 75
Shutdown ......................................................................................................................................... 76
Operating malfunctions and troubleshooting ................................................................................... 77
MAINTENANCE ..................................................................................................... 81
7.1
General ............................................................................................................................................ 81
7.2
7.3
Regular maintenance ...................................................................................................................... 82
7.4
Maintenance schedule .................................................................................................................... 84
7.5
Fasteners......................................................................................................................................... 85
7.6
Lubrication ....................................................................................................................................... 87
7.6.1
Oil lubrication......................................................................................................................................... 87
7.6.2
Grease lubrication................................................................................................................................... 90
7.7
Aligning the coupling ....................................................................................................................... 92
7.8
Installing and removing the pull-out unit .......................................................................................... 93
7.8.1
Removing the pull-out unit ..................................................................................................................... 94
7.8.2
Mounting the pull-out unit...................................................................................................................... 95
7.9
Changing the impeller and the front lining ....................................................................................... 96
7.10 Trimming the impeller ...................................................................................................................... 99
7.11 Changing the shaft seals ............................................................................................................... 100
7.11.1
Changing the Andritz cartridge mechanical seal-single and double ..................................................... 100
7.11.2
Changing the standard cartridge mechanical seal-single and double ................................................... 102
7.11.3
Changing the single standard mechanical seal ..................................................................................... 104
7.11.4
Changing the tandem standard mechanical seal ................................................................................... 106
7.11.5
Changing the stuffing box packing and the shaft protection sleeve ..................................................... 108
7.12 Changing the anti-friction bearings ............................................................................................... 112
7.13 Disassembly and disposal ............................................................................................................. 114
8
8.1
8.2
8.3
8.4
8.5
TECHNICAL DATA ............................................................................................... 116
Data sheet ..................................................................................................................................... 116
Characteristic curve ....................................................................................................................... 116
Dimensional drawing ..................................................................................................................... 116
Coupling ........................................................................................................................................ 117
Shaft seal ....................................................................................................................................... 117
Page 4 of 117
Page 5 of 117
1
INTRODUCTION
This manual is part of the ANDRITZ AG technical documentation for the
pump. It is intended to provide the operator with the basic knowledge
required for proper, safe and economical use of the equipment delivered
by ANDRITZ AG. Observing these instructions helps avoid hazards and
reduce repair and downtime costs, as well as increasing the reliability
and useful life of the machines.
1.1
Use
Target group
This operating manual is intended for users with a knowledge of
mechanical engineering and is for the exclusive use of the operator of
the mill and his personnel.
Personnel entrusted with work on the machine must have read and
understood these operating instructions and comply with them. This
refers in particular to the following tasks:

Handling, starting and stopping

Troubleshooting

Maintenance and upkeep

Haulage

Maintenance and disposal of process materials, cleaning of machine
and area around the machine.
The following sections are especially important:

The Chapter on SAFETY,

The safety instructions contained in various other chapters
Supplementary
instructions
The mill operator shall complete this manual by adding national
regulations on safety at work, health protection and environmental
protection.
Instructions on any special operational conditions concerning work
organization, sequence of work/operations and the personnel assigned
to the job shall also be added. This also includes instructions on
supervising and reporting obligations.
Safekeeping
Keep the entire operating manual near the place where the machine is
installed and within easy reach.
1.2
Standards and guidelines
The pump is delivered together with a CE declaration of conformity
according to Machinery Directive 2006/42/EC Annex II, 1.A. It is
confirmed that European standards (harmonized) EN 809 and EN ISO
12100, Parts1 and 2, have been observed. Auxiliary electrical equipment supplied,
such as motors, measuring instruments, ... carry a CE marking
(if they fall within the scope of a guideline, for example the low-voltage or
EMV guideline).
Page 6 of 117
1.3
How to use the manual
Presentation


Chapter and paragraph headings are printed in capitals in the
continuous test
SAFETY
Designations of indicating and handling elements are written in inverted
commas in the continuous text.
Operate switch “xxx”

Pictograms
Lists without numbering do not require operations to be carried out in a
certain order.
The following pictograms are used in the manual:
Warning signs.
Warning signs are shown with an explanation of the type
of the hazard.
The meaning of the different graduations of hazards is
described in the Chapter on SAFETY.
Marks an instruction on handling of the machine of
system.
Marks a useful piece of information

Work steps
(operations)
Marks a cross-reference to another Chapter with absolute
path indication.
e.g.  /ACP-Pump/SAFETY
Work steps are presented in tables. Work steps are numbered and must be
carried out in the order specified.
Page 7 of 117
Item numbers
411.2
The item numbers shown in this format refer to the assembly
drawing and the parts list.
Numbering of
pages, tables and
figures
Pages
consecutive numbering of Chapters
2-1
Tables
Figures
Tab. + Continuous numbering of Chapters
Fig. + Consecutive numbering of Chapters
Tab.2-1
Fig.2-1
Tab.
Table
Fig.
Figure
Abbreviations
1.4
Warranty and guarantee
Andritz AG’s general terms of delivery and sale shall apply.
Guarantee and liability claims on Andritz AG shall become void if personal
injury or material damage is caused by one or several of the following:

Use of the machine/system for any purpose other than its designated
use.

Non-conformity of erection work, start-up and handling of the
machine/system.

Non-observance of the safety instructions in the manual.

Non-authorized structural changes to the machine/system.

Non-observance of the maintenance and upkeep instructions.
In the event of a claim for repair under guarantee, ANDRITZ AG reserves the
right to assess the damage to the machine/system.
Page 8 of 117
1.5
Manufacturer’s name and address
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Our service department will be pleased to help you and can be contacted at:
Andritz AG
Stattegger Strasse 18
A-8045 Graz
Service department for pumps
Tel.:
+43/316-6902-2706
Fax:
+43/316-6902-413
Email:
Johann.Strasser@andritz.com
In case of emergency outside working hours
Tel.: +43 316 6902-0
1.6
Copyright
The operating manual is protected by copyright. All usual rights reserved. It
must not be wholly or partly reproduced without authorization by Andritz. All
rights shall also be reserved for any patents granted, registration of trade
marks and technical modifications without prior notification.
2010 Andritz AG
Page 9 of 117
2
SAFETY
2.1
General safety regulations
The chapter on safety contains general safety regulations which must be
observed when working on the machine/plant.
In addition, the chapters in the operating manual contain further safety
regulations. These are marked by DANGER SIGNS.
Safety instructions on components not supplied by Andritz AG are contained in
the descriptions of the components ( /ACP-PUMP/SUPPLIER
DOCUMENTATION). The safety instructions supplement ANDRITZ AG’s
operating instructions.
All safety instructions must be observed. Disregarding the safety instructions
may cause a risk to life and limb, environmental pollution hazards and damage
to property.
2.2
Danger and warning signs
The entire SAFETY chapter is of extreme importance and relevant to safety. The
information in this chapter, therefore, is not marked with special danger
symbols.
The Chapters on ERECTION WORK, START-UP, OPERATION and
MAINTENANCE in this Manual are marked by a pictogram. The following
warning signs are used:
DANGER
This symbol indicates there may be a risk to life and limb.
Non-compliance with the warning signs may lead to serious health
problems or even fatal injuries, and can cause extensive damage to
property.
This symbol points to an imminent health risk, as well as a risk of
environmental pollution and of damage to property.
WARNING
Non-compliance with the warning sign may cause moderate health
problems and/or extensive environmental pollution and damage to
property.
This symbol points to a dangerous situation.
Non-observance of these signs may cause environmental pollution and
damage to property.
CAUTION
Further symbols and pictograms used are described under INTRODUCTION.
Page 10 of 117
2.3
Designated use
The centrifugal pump should only be used according to the specifications
forming part of the purchase order.
Any change in the application must be checked by the operator and, if
necessary, approved by Andritz AG.
Non-observance of the application can lead to environmental or property
damage, or to personal injury.
Any modifications to the scope of supply made without the agreement of Andritz
AG are considered contrary to the designated use.
The term designated use shall also include adherence to the operating
instructions, observance of the operating, inspection and maintenance
conditions and of the regulations on cleaning and upkeep.
Please also observe the type specification ( /TECHNICAL
DESCRIPTION/TYPE SPECIFICATION Chapter 3.5), and the operating
limits ( /TECHNICAL DESCRIPTION/OPERATING LIMITS Chapter
3.6)
2.4
General remarks on machine/plant safety
The centrifugal pump has been built in accordance with state-of-the-art
standards and the recognized safety rules. Nevertheless, its use may constitute
a risk to life and limb of the user of third parties, of cause damage to the
machine/plant and to other material property.
The centrifugal pump may only be operated when in perfect condition and with
due consideration to safety and the risks involved. All protective devices and the
emergency cut-out devices must be in place and fully functional.
Malfunctions and unforeseen changes in the centrifugal pump must be
remedied immediately.
Page 11 of 117
2.5
User’s obligations
Designated use
The user of the centrifugal pump is responsible for its designated use.
Work instructions
In addition to the operating instructions, applicable legal stipulations and
other rules governing the safety at work, health and environmental
protection must be observed and personnel instructed in them.
Qualification
of assigned
personnel
The centrifugal pump may only be operated, maintained and serviced by
authorized, skilled personnel with hands-on training.
Personnel must not be below the legal minimum age.
Any person undergoing training, serving an apprenticeship or being
instructed must not work on the centrifugal pump except under the
supervision of an experienced person.
Instructions
The user’s operating and maintenance personnel will be instructed by
manufacturer personnel or his contractual distributor upon completion of
installation work.
The user undertakes to have new, additional operating and maintenance
personnel instructed in machine and maintenance of the centrifugal
pump to the same extent and applying the same care, and with due
consideration to the safety instructions.
Workers entrusted with the transportation, erection work and start-up of
the centrifugal pump must have read and understood the operating
instructions, especially the chapter on SAFETY, the safety instructions
concerning a certain activity, as well as the safety instructions issued by
sub-suppliers.
Definition of areas of
responsibility
The user shall be responsible for:



definition of the machine operator’s responsibility and his right to give
instructions
Definition of the contents and responsibility for keeping the records
on functioning and any failure of the monitoring equipment (log book)
Personnel areas of responsibility in terms of operating, Tooling,
maintenance and upkeep.
Page 12 of 117
Inspections
The operator undertakes


Attaching safety
devices
The user shall ensure that the following equipment, regulations, symbols
and instructions are mounted in the production area;













High-voltage
protection
To check at regular interval whether the safety instructions and
regulations governing work on the centrifugal pump are observed.
To carry out regular training to confirm the level of knowledge of the
operating and maintenance personnel.
Safety devices and regulations (see Chapter 2.7)
Fire prevention regulations
Markings on the floor for driveways, protective fencing and danger
areas (yellow)
Fencings and covers
Railings (foot, center and chest height)
Emergency lighting
Emergency-off switch
Repair switch for drive motors
Signs on fire-fighting equipment
Signs for emergency calls
Direction arrows to exits
Direction arrows to escape routes
Signs to first-aid post
The operator shall provide suitable earthing and high-voltage protection
equipment.
Page 13 of 117
2.6
General obligations of personnel
To avoid personal and material damage anybody working on the machine shall

Observe the safety instructions in the operating regulations and on the
centrifugal pump itself.

Stop and secure the centrifugal pump in case of a safety-relevant functional
disorder. Report disorders and have them repaired immediately.

Do not perform any work in a manner disregarding safety considerations.

Use only the machine accesses, paths and passages foreseen for this
purpose.

Do not touch moving and rotating parts and/or reach out beyond them.

Keep the machine and the work place clean. Do not place tools or other
objects on the centrifugal pump.

Do not wear any garments/pieces of jewelry which might get stuck on
rotating/moving pump parts; this includes ties, scarves, rings and
necklaces.

Not wear long hair down.

Familiarize yourself with the function and any failure of machine monitoring
equipment (log book) before starting work.

Refrain from smoking in the vicinity of the centrifugal pump.

Personal protective apparel must be worn when working on the centrifugal
pump. (see Section 2.8)

Due to the high temperatures, high pressure and humidity, people wearing
glasses may find that their glasses steam up, thus exposing the wearer to a
risk of injury.

The operating personnel must be acquainted with the safety data sheets in
order to be able to recognize how dangerous the chemicals can be.

In order to identify the risks of high pressure (up to 25 bar), the personnel
must know the technical data of the centrifugal pump, as well as its place of
installation.
Page 14 of 117
2.7
Safety devices
The centrifugal pump must not be operated without effective safety equipment.
Safety equipment must not be circumvented, dismantled or made unserviceable
during operations. The safety equipment is there to protect operating personnel.
Safety equipment and access thereto must be kept free.
Safety covers
The centrifugal pump must not be operated without safety covers mounted.
Check in particular that the coupling guard does not have any
deformations!
Fig. 2-1 shows the protective covers for the centrifugal pump.
Safe guard for
sealing
chamber
Coupling guard
Fig. 2-1 Safety covers at the ACP pump
Page 15 of 117
Earthing
Indicative, warning
Indicative, warning and prohibiting signs must be observed. They must be
and prohibiting
signs
Checked regularly for legibility and completeness and they must not be
removed or obstructed.
The following indicative, warning and prohibiting signs are attached to the
machine.
Hot surface
Chemicals:
If the pump is used in the chemicals sector, the operator must mount
appropriate safety instructions on the plant.
Examples of signs required where chemicals are used:
Warning against
toxic substances
Emergency-off
switch, safety
shutdown
Caustic
substances
The pump is usually part of a plant or system.
The operator is responsible for installation of EMERGENCY OFF/STOP
devices so that the plant can be brought to a halt in an emergency.
Page 16 of 117
2.8
Personal protective apparel
General protective
apparel
Operating personnel must use and carry personal protective equipment along
with them in accordance with the national regulations or as specified by the
plant operator.
It should be compulsory to wear hard-toed boots throughout the entire mill
premises.
In addition to the regulations applying, we recommend using the following
safety equipment for certain work:
Activity
Safety equipment
Time spent in the immediate
vicinity of the machine while it is
running
Taking pulp samples
Field installation and
maintenance work for which parts
of the machine have to be
removed
Tab. 2-1
recommended safety equipment for certain work
Key to symbols
Tab. 2-2
Protective clothing to prevent the
pulp from coming into contact
with the skin
Safety shoes as protection
against foot injuries
Gloves to prevent hand injuries
Ear protection to prevent damage
to hearing
Goggles to prevent eye injuries
Standard hard hat as protection
against head injuries
Purpose of the safety equipment
Page 17 of 117
2.9
Safety at the machine installation site
Adequate lighting must be provided (industrial lighting).
The foundations must be sized to withstand the loads caused by the centrifugal
pump. The customer will be provided with a load plan.
The pump must be easily accessible. The operator must provide safe means of
access (e.g. ladders, platforms…)
Area around machine and marked escapes to be kept clear. Area around
machine must be marked as danger zone.
Make sure machine and surrounding area are kept clean. In particular, oil and
grease on the floor and on machine elements may cause slipping. Thus, they
present a considerable risk of injuries, particularly in combination with tools.
The floor around the centrifugal pump must be provided with a non-slip finish.
In order to prevent any falls from or damage to the machine, it is forbidden to
climb onto machine elements or on the machine (except for the treading areas
provided). Use ladders or similar equipment in accordance with recognized
standards.
Ramps, platforms and lifts must be used to avoid injury or excessive physical
effort.
2.10
Temperature
As the temperature of the medium can exceed 73°C, the housing and covers
prevent from direct contact with the medium. Danger symbols mounted on the
machine warn against the hot surface. It is compulsory to wear personal safety
equipment in the immediate vicinity of the pump.
The operator is responsible for informing new personnel on the danger of burns
and for implementing further safety mwasures, e.g. insulation or access
restrictions.
No maintenance work should be carried out until the hot surface has cooled
down.
The centrifugal pump can be designed for a media temperature of up to180°C. If
media with temperatures higher than 65°C are to be pumped, the operator must
take the necessary safety measures (e.g. safety devices, protective gloves,
training of operating staff, etc.).
2.11
Noise
The total noise emissions from all machines in the production room can restrict
spoken communication and impair hearing.
The machine is designed such that no operator is required in the immediate
vicinity of the machine. Appropriate hearing protection should be worn
throughout maintenance and adjusting work while the machine is running.
Page 18 of 117
2.11.1
Noise levels (dB(A))
990 u/min
1180 u/min
1450 u/min
1780 u/min
ACP 65-315
70
70
72
75
ACP 100-500
70
70
72
76
ACP 65-250
70
70
71
ACP 100-315
70
70
ACP 125-400
70
ACP 150-500
3000 u/min
3560 u/min
80
83
73
79
83
71
75
82
84
70
73
76
70
72
76
77
ACP 100-250
70
70
72
76
81
84
ACP 125-315
70
71
73
77
ACP 150-400
70
72
75
78
ACP 200-500
70
73
77
79
ACP 300-700
70
76
ACP 125-250
70
71
75
79
82
85
ACP 150-315
70
70
71
75
ACP 200-400
70
73
76
79
ACP 400-700
70
75
ACP 250-315
70
71
73
77
ACP 300-400
70
72
75
78
ACP 450-550
70
73
ACP 600-700
70
74
Page 19 of 117
2.12
Electrical equipment
All work on the electrical equipment, without exception, must be carried out by
skilled electricians.
Any form of contact with electrical equipment may cause fatal injuries. Before
beginning any maintenance or repair work, the operator must disconnect the
energy supply to all drives securely. This can be achieved with a maintenance
switch, lockable racks in the MCC, or with other suitable measures that comply
with the safety regulations.
Employees performing work on live parts should be accompanied by an
assistant who can operate the emergency switch if necessary.
Users of medical electronic equipment, such as pacemakers, must not enter the
electric danger zone.
Earthing
Machine must be earthed to avoid electrostatic loading. Machine, gears and
motors must be connected to the earthing system.
Machine must be earthed to avoid electrostatic loading.
Proper earthing must be restored after conducting maintenance work (e.g.
check and set the earthing resistance)
2.13
Fluids (liquids, gases, vapor or smoke)
Unintentional chemical reactions may take place in the medium during a
prolonged standstill and hazardous fumes may be produced.
The machine must be thoroughly cleaned after prolonged stoppages. The area
must be adequately ventilated.
Before beginning work on the machine, ensure that no liquids, gases, vapors or
smoke can enter the working area from feed pipes, discharge pipes or shafts.
If it is not possible to reliably exclude the risk of liquids, gases, vapours or
smoke flowing in, all persons working in the danger zone must be quipped with
a safety harness and a safety rope. Each worker must be monitored by a
second person outside the danger zone. It must always be possible to evacuate
a worker from the danger zone without delay.
Any leakage (e.g. at the shaft seal) of hazardous media (e.g. explosive, toxic,
hot) must be drained off in such a way that there is no risk to individuals, nor to
the environment. Any legal regulations must be observed.
Page 20 of 117
2.14
Oils and greases and cleaning agents
The safety instructions for the products concerned must be observed when
handling oil, grease and other chemical substances.
Suitable skin protection is required when handling aggressive media. See
manufacturers’ information for the type of skin protection required.
Also observe relevant requirements for disposal
2.15
Chemicals
The centrifugal pump can be used in the chemical sector (except in chlorine
bleaching and in the chlorine dioxide area) of the pulp and paper industry.
The following chemicals can be pumped:

Hydrogen peroxide H2O2

Caustic soda (sodium hydroxide) (NaOH)

Silicate

DTPA
Hydrogen peroxide (H2O2) and caustic soda (NaOH) can irritate or even burn
the skin and mucous membrane, particularly the eyes, and can also lead to
inflammations of the respiratory system.
In addition, please note that hydrogen peroxide (H2O2) is not combustible, but
enhances the combustibility of other substances.
Reactions
In reactions with other substances, hydrogen peroxide (H2O2) and caustic soda
(NaOH) can lead to highly exothermic reactions, heat generation, and danger of
ignition or generating of inflammable gases or vapours, even to a risk of
explosion.
Safety data sheets
If chemicals are used, the measures prescribed in the safety data sheets for the
individual chemicals must be observed.
The user shall be responsible for the following, among other things:

Staff wearing personal safety attire, particularly adequate eye protection

Installing water connections and emergency showers in order to rinse the
eyes or skin under running water in the event of an emergency and have a
source of drinking water if any chemicals are inadvertently swallowed.

Providing medical treatment in emergencies

Preventing any chemical reactions that can lead to a risk of fire or
explosion

Regular training on the properties and handling regulations for the
chemicals used.

Mounting of safety signs on the plant (e.g. warning against toxic or
corrosive substances)

Mounting devices for flushing the pump (e.g. the inlet flange) in order to
Page 21 of 117
clean the pump from aggressive media.

Interlocking the chemical feed so that no more chemicals can flow into the
pump when pump is shut down.

Emptying the vent line safely to prevent from possible contact with
chemicals.
Page 22 of 117
3
Technical Description
3.1
General description
3.1.1
Field of application
The centrifugal pump is used in continuous operation to pump specified liquids
and various pulps in the paper industry.
(See chapter headed Technical Data)
Fig. 3-1
Centrifugal pump
Page 23 of 117
3.1.2
Design
This spiral casing centrifugal pump is carried out in process design. The impeller,
the wear lining, the casing cover and the stuffing box body with the shaft seals
and the bearing support can be assembled and disassembled without detaching
the suction and delivery pipes.
Impeller(230))
Function: Accelerating the medium by charging it with energy.
Design: Semi-open impeller with vanes on the back.
Spiral casing (102)
Function: Guiding the medium with a favorable flow pattern, converting speed
energy into pressure energy.
Design:

Pressure-sealed pump casing with delivery and suction channels.

Suction and delivery flange.

Holds the bearing housing with bearing assembly, shaft and impeller.
Standard design . . . . . . . . . . . . . . . . . . . . . . . . . . single spiral casing
Special design . . . . . . . . . . . . . . . . . . . . . . . . . . . Double spiral casing
Pump shaft (211)
Function: Holding the impeller, shaft seal, bearing assembly and coupling.
Transmitting the drive energy to the impeller and thus, to the medium.
Design: Sturdily dimensioned drive shaft
Bearings
Function: Interface between stationary and rotating parts. Absorption of axial
and radial forces.
Design:
Impeller side: . . . Two angular contact ball bearings (321.1) with steel
cage.
Drive side. . . . . One deep groove ball bearings (321.2) with steel cage.
Shaft seal
Depending on operating requirements, there is a choice of eight different
shaft seals:

Andritz cartridge mechanical seal - single

Andritz cartridge mechanical seal - double

Standard cartridge mechanical seal - single

Standard cartridge mechanical seal – double

Single standard mechanical seal

Tandem mechanical seal

Stuffing box packing

Dynamic shaft seal
Page 24 of 117
3.2
Main components of the centrifugal pump
3.2.1
Centrifugal pump with base frame
A
C
B
D
Fig. 3-2
E
Item Component
A
B
Centrifugal pump, complete
Coupling (840)
C
Coupling guard (681)
D
Base frame (891)
E
Sliding rail (593)
Tab. 4-1
F
Item Component
F
Motor (800)
Page 25 of 117
3.2.2
Centrifugal pump
102
135.1
230 161
430
330
183
680
554.1, 920.1, 902.1
Fig. 4-3
Main section - centrifugal pump
Item Component
Item Component
Volute casing
135.1 Front lining
330
102
680
Bearing support
Safety guard for sealing chamber
230
Impeller
183
Supporting leg
430
Shaft seal
161
Casing Cover
Tab. 4-2
Principal section ACP pump
Page 26 of 117
3.2.3
Bearing support
350
636.1
321.1
321.2
636.1
211
550.2
421.2
507.2
550.1
421.1
507.1
904.2
672
904.1
Fig. 4-4
Item Component
350
211
Bearing housing
Shaft
321.1 Angular contact ball bearing
321.2 Deep groove ball bearing
550
Splash ring washer (550.1,550.2)
507
Splash ring (507.1,501.2)
Tab. 3-3
903.2
Grease lubrication
Item Component
421
Rotary shaft seals (421.1, 421.2)
672
Vent screw
642
Oil level indicator
636.1 Grease lubricating nipple
904
Set screw
Main components for the bearing support
Page 27 of 117
350
903.3
321.1
321.2
903.4
211
423.2
914.10
411.10
423.1
672
914.11
411.11
633
Fig. 3-5 Oil lubrication
642
Item Component
Bearing housing
Shaft
Item Component
672
Plug
Vent screw
321.1 Angular contact ball bearing
914
Socket head cap screw
321.2 Deep groove ball bearing
411
Sealing washer
633
Constant level oiler (option)
350
211
423
Bearing isolator (423.1,423.2)
642
Oil level indicator (option)
Tab. 3-4
903
Main components for the bearing support
Page 28 of 117
3.3
Type of seal
Fig. 3-6 Andritz cartridge mechanical seal - single
Fig. 3-7 Andritz cartridge mechanical seal - double
Fig. 3-8 Standard cartridge mechanical seal - single Fig. 3-9 Standard cartridge mechanical seal - Double
Type: A1
Type: A3
Type: A2
Fig. 3-10
Single mechanical seal
Fig. 3-11 Single mechanical seal
Page 29 of 117
Not available yet
Fig. 3-14
Fig. 3-15 Dynamic shaft seal
Page 30 of 117
3.3.1
Function: Seal between medium and the atmosphere. The mechanical seal
is lubricated by the medium to be pumped.
433.1
Atmosphere
Medium
914.1
Item
Component
Item
433.1 Mechanical seal
Component
914.1 Screw
Tab. 3-5 Andritz cartridge mechanical seal - single
Application limits:
T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C
p max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar
n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)
Bearing suppport size
42
48
60
75
100
Shaft diameter D[mm]
42
48
60
75
100
Seal diameter D1[mm]
53
60
70
85
115
Tab. 3-6
Sizes - Andritz cartridge mechanical seal – single
Page 31 of 117
3.3.2
Function: Seal between medium and the atmosphere by sealing water
between the medium-side and the atmosphere-side seal in order to
guarantee functioning of the mechanical seal within special application
limits.
433.1
Atmosphere
Medium
914.1
Fig. 3-17
Item
Component
Item
Tab. 3-4
Component
914.1 Screw
Application limits:
T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C
p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar
n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)
42
48
60
75
100
42
48
60
75
100
53
60
70
85
115
Sealing water pressure [bar]
0.5-12 0.5-12 0.5-12 0.5-12 0.5-12
Sealing water quantity [1/min]
Tab. 3-7
2
3
3
4
4
Sizes - Andritz cartridge mechanical seal – single
Page 32 of 117
Sealing water data:
Pressure
0.5 bar min. - 12 bar max.
Quality
Pure water
Mechanical contamination: 80 microns max.
Temperature
10°C min. - 30°C max.
Solids content
2 mg/l max.
Tab. 3-8
Monitoring
Sealing water data for Andritz cartridge mechanical seal
In order to guarantee proper operation the sealing water must be
monitored with suitable monitoring units according to the diagrams (Fig.
4-18, Fig. 4-19).
Sealing water connection and monitoring for the tandem mechanical
seal:
Fig. 3-18 Unpressurised
Fig. 3-19 Pressurised
Page 33 of 117
3.3.3
Standard cartridge mechanical seal - single
412.5
902.4, 920.4, 554.4
433
.1
504
551.2
Atmosphere
Medium
914.1
145
Item
Component
Item
Component
145
Adapter
412.5 O-ring
914.1 Screw
504
902.4 Bolt
Spacer
Tab. 3-9 Standard cartridge mechanical seal - single
Application limits:
T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C
p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar
n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)
Page 34 of 117
42
48
60
75
100
42
48
60
75
100
53
60
70
85
115
0.5-12 0.5-12 0.5-12 0.5-12 0.5-12
2
3
3
4
4
Tab. 3-10 Sizes - Standard cartridge mechanical seal – single
Sealing water data:
Pressure
Quality
Pure water
Temperature
10°C min. - 30°C max.
Solids content
2 mg/l max.
Tab. 3-11 Sealing water data for standard mechanical seal
Monitoring
In order to guarantee proper operation the sealing water must be monitored
with suitable monitoring units according to the diagrams (Fig.4-21, Fig. 4-22).
seal:
Fig. 3-22 Pressurized
Page 35 of 117
3.3.4
Standard cartridge mechanical seal - double
Function: Seal between medium and the atmosphere by sealing water
between the medium-side and the atmosphere-side seal in order to
guarantee functioning of the mechanical seal within special application
limits.
902.4,920.4,
554.4
433.1
504
551.2
Atmosphere
Medium
914.1
412.5
145
Fig. 3-23
Item
Component
Item
Component
145
Adapter
412.5 O-ring
914.1 Screw
504
902.4 Bolt
Spacer
Tab. 3-12 Andritz cartridge mechanical seal - single
Application limits:
T max: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°C
p max:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar
n max:
. . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)
Page 36 of 117
42
48
60
75
100
42
48
60
75
100
53
60
70
85
115
0.5-12 0.5-12 0.5-12 0.5-12 0.5-12
2
3
3
4
4
Tab. 3-13 Sizes - Andritz cartridge mechanical seal – single
Sealing water data:
Pressure
Quality
Pure water
Temperature
10°C min. - 30°C max.
Solids content
2 mg/l max.
Tab. 3-14 Sealing water data for tandem mechanical seal
Monitoring
monitored with suitable monitoring units according to the diagrams (Fig.
3-24, Fig. 3-25).
seal:
Fig. 3-25 Pressurized
Page 37 of 117
3.3.5
Single standard mechanical seal
145
Type: A1
504
551.2
433.1
Atmosphere
Medium
Type: A2
914.1
412.5
509
145
433.1
Type: A3
Medium
Atmosphere
914.1
914.12
412.5
Fig. 3-26 Single mechanical seal
Page 38 of 117
Item
Component
Item
145
Adapter
433.1 Mechanical seal (MG12)
504
Component
412.5 O-ring
914.1 Screw
Spacer
Tab. 3-15 Single standard mechanical seal – type A1-MG12S14
Item
Component
Item
145
Adapter
Component
412.5 O-ring
914.1 Screw
Tab. 3-16 Single standard mechanical seal – type A2- 578
Item
Component
Item
Component
145
Adapter
412.5 O-ring
914.1 Screw
509
914.12 Screw
Fastening ring
Tab. 3-17 Single standard mechanical seal – type A3 – SR6
Application limits:
T max:. . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . . . . . 100°C
p max:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 bar
n max:. . . . . . . . . . . . . . . . . . . . . . . 3000 r.p.m. (3600 r.p.m. at 60 Hz)
Bearing support size
42
48
60
75
100
42
48
60
75
100
53
60
70
85
115
Tab. 3-18 Sizes – Single standard mechanical seal
Page 39 of 117
3.3.6
Function: Seal between medium to be conveyed and the atmosphere
formed by packing rings and sealing water.
451
902.4
920.4
554.4
458
412.8
524
461
914.1
452
Fig. 3-30 Stuffing box packing
Item
412.5
Component
Item
Component
451
452
Stuffing box casing
Stuffing box gland
461
524
Shaft protection sleeve
458
Sealing water ring
412.5/8 O-ring
902.4
Bolt
914.1
Tab. 3-24
Screw
42
48
60
75
100
42
48
60
75
100
53
60
70
85
115
Packing diameter D2[mm]
65
70
100
130
Packing [mm]
10x10
10 x10 10x10
12x12
12x12
1+3
1+3
2+3
2+3
Number
80
2+3
3-5
3-5
3-5
3-5
3-5
Sealing water quantity [l/min]
2
3
3
3
4
Tab. 3-25
Sizes - Stuffing box packing
Page 40 of 117
Sealing water data:
Sealing water
pressure
3 - 5 bar +inlet pressure
Quality
Pure water
Temperature
10°C min. - 30°C max.
Solids content
2 mg/l max.
Tab. 3-26
Monitoring
Sealing water data for stuffing box packing
monitored with suitable monitoring units according to the diagram (Fig.
3-22).
Sealing water connection and monitoring for the stuffing box:
Page 41 of 117
3.4
Type specification
3.4.1
Applicable standards
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 2858
Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 5199
Inspection (Q, H, NPSH) . . . . . . . . . . . . . . . . . . . . . ISO 9906 Class 

Product safety . . . . . . . . . . . . . . . .EN 809, EN 12100-1, ISO 12100-2
Flanged drilling . . . . . . . . . . ISO 2084, PN 10 (DIN 2501, SFS 2123)
. . . . . . . . . . . . . . . . . . . . . . . ISO 2084, PN 16 (DIN 2501, SFS 2123)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ISO 2084, PN 25
Special flange bore . . . . . . . . . . . . . . . . . . . . . . . . . . . JIS B2210 10K
Special flange bore . . . . . . . . . . . . . . . . . . . . . . . . . . . JIS B2210 16K
Special flange bore . . . . . . . . . . . . . . . . . . . . . ANSI B 16.1 Class 125
Special flange bore . . . . . . . . . . . . . . . . . . . . . ANSI B 16.5 Class 150
3.4.2
Model designation
ACP 400 - 700
Impeller diameter in Q and H optimum
Nominal width of delivery branch (mm)
Centrifugal pump Series ACP
Fig. 4-33 Type code
Type plate
Each centrifugal pump has a type plate mounted on the spiral casing
showing the main pump data.
Q
Flow rate ( m3/h)
H
Head (m)
P
Motor output (kW)
n
Motor speed (rpm)
C
Consistency (%)

Spec. gravity (kg/m3)
pmax
Max. permitted pump pressure at 20°C
tmax
Max. permitted medium temperature at pmax 20°C
Fig. 3-34 Type plate
Page 42 of 117
3.5
Application limiting values
The limit values shown in the present Chapter should not be
exceeded under any circumstances!
CAUTION
The limit values shown for the centrifugal pump Series “ACP” stated in
the present Chapter should not be exceeded under any circumstances.
Pressure limit
value
The maximum permitted pressure for each pump as stated on the rating
plate should not be exceeded.
Temperature limit
value
The maximum permitted operating temperature for each pump as stated
on the rating plate should not be exceeded.
Spiral casing made of steel casing
Material 1.4460
Material 1.4408
Temperature [0C]
Spiral casing made of steel casing
Material 1.4460
Material 1.4408
Temperature [0C]
Fig. 3-35 Application limiting values
Page 43 of 117
Shaft seal
The application limit for the appropriate shaft seal (Andritz cartridge
mechanical seal – single / double, Standard cartridge mechanical seal –
single / double, Single standard mechanical seal, Tandem standard
mechanical seal, Stuffing box packing, Dynamic shaft seal) can be
obtained in writing from the pump manufacturer and is also shown in the
data sheet (see Chapter on “Technical Date”)
Material to be
conveyed/medium
The centrifugal pump ACP is used to pump non-combustible liquids and
pulps.
Before planning the use of combustible liquids (solvent, petrol, alcohol
etc.), it is essential to consult ANDRITZ AG beforehand!
Lower flashpoints of combustible liquids can lead to hazards due to fire or
explosion.
Zone allocation
The ACP centrifugal pump is not intended for use in a potentially explosive
environment / atmosphere. The ACP centrifugal pump is intended for use
outside a zone, according to guideline 1999/92/EG (gases/vapors and
dust).
A change of zone e.g. to zone 2 or zone 22 must be documented in writing
and can entail additional costs as well as delays in delivery.
Page 44 of 117
Permitted forces
and torques
The permitted forces and torques according to Table (Tab.3-27) should
not be exceeded.
As a general principle, the suction and delivery pipes must be connected
up stress-free. We recommend checking this item before initial start-up.
The values stated apply to the spiral casing made of steel casing
with base frame grouted in.
For other designs, the following figures apply:
Spiral casing made of grey cast iron
with frame grouted in…………………35% of the figures stated
Spiral casing made of steel casting
Frame not grouted in…………………70% of the figures stated
essure Flange
Force N
Diameter
DN
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
550
600
Fy
700
850
1 000
1350
1 700
2 050
2 700
3 200
4 050
5 400
6 750
8 050
9 400
10 750
12 100
13 450
14 800
16 150
Fz
850
1 050
1 250
1 650
2 100
2 500
3 350
3 950
5 000
6 700
8 350
10 000
11 650
13 300
14 950
16 600
18 250
19 900
Fx
750
900
1 100
1 500
1 850
2 250
3 000
3 550
4 500
6 000
7 450
8 950
10 450
11 950
13 450
14 950
16 450
17 950
Torque N.m
ΣFb
1 300
1 650
1 950
2 600
3 300
3 950
5 250
6 200
7 850
10 450
13 050
15 650
18 250
20 850
23 450
26 050
28 650
31 250
My
600
750
900
1 000
1 100
1 150
1 250
1 500
1 750
2 300
3 150
4 300
5 500
6 900
8 500
10 250
12 200
14 400
Mz
700
850
1 050
1 150
1 200
1 300
1 450
1 900
2 050
2 650
3 650
4 950
6 350
7 950
9 800
11 800
14 050
16 600
Mx
900
1 100
1 300
1 400
1 500
1 600
1 750
2 100
2 500
3 250
4 450
6 050
7 750
9 700
11 950
14 450
17 100
20 200
ΣMb
1 300
1 600
1 900
2 050
2 200
2 350
2 600
3 050
3 650
4 800
6 550
8 900
11 400
14 300
17 600
21 300
25 300
29 900
Page 45 of 117
Suction Flange
Force N
Diameter
DN
25
32
40
50
65
80
100
125
150
200
250
300
350
400
450
500
550
600
Tab. 3-27
Fy
750
900
1 100
1 500
1 850
2 250
3 000
3 550
4 500
6 000
7 450
8 950
10 450
11 950
13 450
14 950
16 450
17 950
Fz
700
850
1 000
1 350
1 700
2 050
2 700
3 200
4 050
5 400
6 750
8 050
9 400
10 750
12 100
13 450
14 800
16 150
Fx
850
1 050
1 250
1 650
2 100
2 500
3 350
3 950
5 000
6 700
8 350
10 000
11 650
13 300
14 950
16 600
18 250
19 900
Torque N.m
ΣFb
1 300
1 650
1 950
2 600
3 300
3 950
5 250
6 200
7 850
10 450
13 050
15 650
18 250
20 850
23 450
26 050
28 650
31 250
My
600
750
900
1 000
1 100
1 150
1 250
1 500
1 750
2 300
3 150
4 300
5 500
6 900
8 500
10 250
12 200
14 400
Mz
700
850
1 050
1 150
1 200
1 300
1 450
1 900
2 050
2 650
3 650
4 950
6 350
7 950
9 800
11 800
14 050
16 600
Mx
900
1 100
1 300
1 400
1 500
1 600
1 750
2 100
2 500
3 250
4 450
6 050
7 750
9 700
11 950
14 450
17 100
20 200
ΣMb
1 300
1 600
1 900
2 050
2 200
2 350
2 600
3 050
3 650
4 800
6 550
8 900
11 400
14 300
17 600
21 300
25 300
29 900
Permitted forces and torques at the pump flange
Page 46 of 117
Z
Y
*)  F ...Vector sum of forces from:
X
Z
FX, FY and 0.47 * Fz at the delivery flange
and FX, FY and 1.0 * Fz at the suction
flange
Y
X
**)  M ...Vector sum of torques:
MX, MY and Mz
Fig. 3-36 Coordinates systems for forces and
torques at delivery and suction flange
Pump Type
Diam.
Suction
Side
Flange
[mm]
Diam.
Pressure
Side Flange
[mm]
ACP 65-315
ACP 100-500
100
150
65
100
ACP 65-250
ACP 100-315
ACP 125-400
ACP 150-500
80
125
150
200
65
100
125
150
ACP 100-250
ACP 125-315
ACP 150-400
ACP 200-500
ACP 300-700
125
150
200
250
350
100
125
150
200
300
ACP 125-250
ACP 150-315
ACP 200-400
ACP 400-700
150
200
200
450
125
150
200
400
ACP 250-315
ACP 300-400
ACP 450-550
250
300
450
250
300
450
ACP 600-700
600
600
Fig. 3-37 Diameters of suction and pressure side flanges
Page 47 of 117
3.6
Performance limits for bearing supports for different shaft
material
The performance limit shown in the table for different shaft materials
must be observed!
Material:1.4462
Tmax=1800C
Material:1.4404
Tmax=1300C
Material:1.4462
Tmax=600C
Material:1.4404
Tmax=1000C
Shaft performance limits (kW)
Tab. 3-28
Bearing
support
42
48
n = 1000 rpm
70
85
n = 1200 rpm
80
60
75
100
230
720
105
270
870
n = 1500 rpm
100
135
330
1180
n = 1800 rpm
125
165
420
1300
n = 3000 rpm
200
-
-
-
n = 3600 rpm
240
-
-
-
n = 1000 rpm
135
175
445
1550
n = 1200 rpm
155
205
520
1880
n = 1500 rpm
205
270
650
2300
n = 1800 rpm
245
340
780
-
n = 3000 rpm
400
540
-
-
n = 3600 rpm
470
-
-
-
n = 1000 rpm
115
151
380
1320
n = 1200 rpm
130
180
450
1580
n = 1500 rpm
170
235
570
1950
n = 1800 rpm
195
280
660
-
n = 3000 rpm
345
450
-
-
n = 3600 rpm
400
-
-
-
n = 1000 rpm
108
140
350
1250
n = 1200 rpm
125
165
420
1480
n = 1500 rpm
160
215
530
1850
n = 1800 rpm
210
260
660
-
n = 3000 rpm
325
425
-
-
n = 3600 rpm
380
-
-
-
Performance limits for different shaft material
The shaft material used for each bearing support is shown in the
Technical Data Sheet for the individual pump.
In case the bearing support is to be used under conditions beyond the values
shown in the table (Tab. 4-30), the manufacturer must be contacted first of all
and a written response requested.
Page 48 of 117
3.7
Technological description
Definition
The centrifugal pump is to be used for an application according to the
purchase order specification to convey specified media observing the
manufacturer’s instructions. If any changes are made and the pump is to
be used for an application not specified, the manufacturer must be
contacted beforehand. (e.g. ATEX sector)
Fig. 3-38 Centrifugal pump
Supply of medium
The medium reaches the impeller through a suction pipe that connects up
to the horizontal axial flange.
Pressure increase
The medium is drawn in by the single-flow impeller in axial direction.
In the impeller, the medium undergoes radial acceleration–thus obtaining
speed energy-due to the rotational energy and the shape of the blades
(changing from axial to radial).In the spiral casing the speed energy is
converted into pressure energy. The medium then enters the delivery
pipe, which is converted into pressure energy. The medium then enters
the delivery pipe, which is connected to the vertical outlet flange.
Page 49 of 117
4
ERECTION and TRANSPORT
4.1
General
This chapter describes certain steps for transport, storage and installation of
the centrifugal pump which may be the responsibility of the user.
Activities which are carried out by ANDRITZ AG, including works assembly,
are not the subject of this description.
4.2
Safety regulations
Disregarding the safety regulations may cause a risk to life and limb
and damage to the machine or its components.
All safety instructions in this Chapter must be strictly observed.
DANGER
General safety
Instructions
All applicable accident prevention rules must be observed.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus forbidden.
Jerking must be avoided. This refers especially to the handling of
pre-assembled machines.
Qualification of
assigned personnel
Transport and unloading to be carried out by personnel especially skilled
with such work.
Workers entrusted with lifting and conveying equipment must have the
required national qualification.
Start-up may only be carried out by trained, skilled workers.
Personal Protective
apparel
The following protective equipment must be worn when carrying out
start-up and transport work:

Hard hat

Protective gloves

Protective shoes

Goggles
Tools
Only use tools of a reputable brand and in good condition for any work
performed on the centrifugal pump.
Page 50 of 117
4.3
Haulage
During transport of the centrifugal pump or loading/unloading
(pump may fall).
DANGER
The loading equipment must bear the name of the manufacturer, the
type of material and the permitted load!
Do not lift machine and transport crates except at the points
marked for lifting by crane or forklift.
Do not step or walk below suspended loads.
Supply
The centrifugal pump is supplied pre-assembled. Machine components
and auxiliary material are packed in crates.
Transport sizes and weights are stated in the shipping documents.
Largest supply weights:
/CENTRIFUGAL PUMP/TECHNICAL DATA
Acceptance



Check whether supply is complete (against shipping documents and
packing list) and in perfect condition.
In the event of transport damage or short supply, do not accept
goods but notify forwarder and ANDRITZ AG’s shipping department.
If there is a hidden defect, notify forwarder and ANDRITZ AG’s
shipping department within two weeks.
Page 51 of 117
Lifting the entire
centrifugal pump
The complete centrifugal pump should only be raised as follows after
unpacking:
The complete centrifugal pump should only be raised if the lifting devices
have been attached under the suction and delivery flanges. The lifting
devices must be short enough to prevent the centrifugal pump from tilting
(Fig. 4-1).
Take care to maintain the balance
CAUTION
Never lift the complete centrifugal pump at the bearing support
window only. This could cause a risk to life and limb and damage to
the pump.
DANGER
Fig. 4-1 Lifting the entire centrifugal pump
Page 52 of 117
Lifting the
centrifugal pump
with free shaft
The centrifugal pump with free shaft should only be raised as follows:


The pump should only be lifted if the lifting devices have been mounted
under the suction branch and at the shaft end.
The lifting devices must be short enough to prevent the pump from
tilting.
CAUTION
Fig. 4-2 Lifting the centrifugal pump
Page 53 of 117
Lifting the pull-out
unit
Attach lifting slings at the points marked in Fig.5-3



Through the bearing support windows
Between the coupling half and the bearing cover
Secure sling to lifting hook and tension slightly.
CAUTION
Fig. 4-3 Lifting the pull – out unit
Page 54 of 117
4.4
Storage
Short-term storage
If the pump is to be stored for less than three months before erection work
begins, please observe the following storage instructions.




Long-term storage
CAUTION
Store the centrifugal pump in a dry place, with suitable protection
against dirt and corrosion.
Packing should not be removed until erection work begins.
If there is no oil or grease in the bearing housing, it must be filled with
oil or grease to protect the bearing assembly against corrosion.
Rotate the pump shaft manually every 2 weeks to prevent damage to
the shaft bearing assembly.
If the pump is to be stored for more than three months before erection work
begins, please observe the following storage instructions.

Store the centrifugal pump in a dry place, with suitable protection
against dirt and corrosion.

Incidentals should be protected against damage and unauthorized
withdrawal by storing in a lockable room.

Drain any liquid from the centrifugal pump.

Rotate the pump shaft manually every 4 weeks to prevent damage to
the shaft bearing assembly.

If the centrifugal pump has a casing of grey cast iron and a stuffing box
packing, remove the packing cord and coat the stuffing box body with
an anti-rust agent.

If there is no oil or grease in the bearing housing, it must be filled with
oil or grease to protect the bearing assembly against corrosion.
The grease or oil in the bearing housing must be renewed before
start-up. Anti-rust agents must be removed entirely.
Page 55 of 117
4.5
Installation
General
Installation takes place in accordance with the sequence plan defined by
ANDRITZ AG.
Disregarding the sequence plan and the installation instructions may
result in hazardous situations causing a danger to life and limb and in
machine damage.
WARNING
The sequence of erection work is important and must be strictly
observed.
Implementation of the various steps must be documented in the certificate
of completion of erection work.
The sequence of erection work is shown in step-by-step tables. Individual
activities are numbered in their order of precedence.
Preservation
Those machine components which are not corrosion-resistant should be
protected against corrosion with preserving grease.
The preservative grease need not be removed.
Required
documentation at
installation site
The following supplementary documentation must be available at the
beginning of erection work.





Foundation and arrangement drawing
Assembly drawings
Documentation on electrical, measuring and control equipment
Parts lists
Packing lists for each individual delivery
Space requirement for erection work, operation and maintenance will be
defined
Together with the ANDRITZ AG representative in charge before the
beginning of erection work.
Ambient temperature during erection work should not be less than 10-15˚
C.
Page 56 of 117
4.5.1
Erection of the centrifugal pump
Foundation
The foundation should be made according to ANDRITZ AG’s foundation
plan.
The following preparations have to be made prior to placing the centrifugal
pump on the foundation:

Mark axes and levels on the foundation.

Check the finish of the foundation before beginning erection work.
Mounting and
foundation work
The foundations are to be laid according to the following table.
Step
1
2
3
4
5
6
7
Activity
Lift centrifugal pump onto the foundation and place on the
support rails.
Height of support rails: 50-100mm
Raise the pump according to Chapter 4.3,Fig.4-1
Align axes and height of the pump according to the plant
requirements.
Transfer the fastening points from the base frame to the
foundation. Drill block holes and insert dowels.
Insert the threaded rod (Item 5) from above and screw on 2
washers and 2 hexagon nuts (Items 4, 6) between the
foundation and the base frame. Screw threaded rod (Item 5)
into the dowel and tighten with the fastening nut (Item 6).
Raise pump unit with the setting nuts (Item 4) and remove the
support rails.
Set the pump unit with setting nuts and tighten on the base
frame with the fastening nuts (Item 3).
Cut off and debar the threaded rod with 5 mm allowance. (see
Fig. 4-4)
Grout base frame in firmly up to the top edge of the special
section tube with non-shrinking cast concrete and leave to set
(Approx. 2 days).
At least concrete strength category according to EN206-1.
C16/20
Tab. 4-1 Foundations
Page 57 of 117
Step
8
Activity
Mounting the motor:
Draw the drilling coupling half flush onto the motor stub and
secure on the feather key with a set screw.
Mount motor on motor base frame (893).
If there are no fastening threads in the motor base frame,
transfer the bore holes from the motor and drill the threads
accordingly.
The axle height of the motor is established by the spacers
(898.1). If the centrifugal pump is ordered specifying the motor,
the correct spacers will be mounted.
Due to the centrifugal pump or components of the centrifugal pump
falling during transport on installation site.
DANGER
Raise centrifugal pump according to the transport instructions in
Chapter 4.3.
Do not step or walk below suspended loads.
Due to parts of the body being jammed or crushed during installation
work.
Wear your personal protective apparel.
DANGER
Transport devices that are forgotten may result in risks to life and
limb and in damage to the machine.
Remove all transport devices.
WARNING
Page 58 of 117
Fig. 4-4 Lifting the pull – out unit
Item
Component
Item
Component
1
Cast concrete according to
EN206-1, C16/20
5
Threaded rod
2
Foundation
6
Fastening nuts
3
Fastening nuts
7
Flush anchor
4
Adjusting nut
Page 59 of 117
4.5.2
Pipework
If pipework is not mounted professionally.
DANGER
This can result in risks to life and limb and in damage to the machine.
Under no circumstances should the centrifugal pump be used to
support a pipe!
If there is risk of dangerous backflow after the pump is shut down, a
reflux check device must be installed in the delivery pipe!
WARNING
Support
When planning the pipework, a supplement must be included for heat
expansion.
Pipes should always be mounted stress-free. During erection work ensure
that the pipes are supported in such a way that no forces, vibrations or
weight can be transferred to the pump.
Maximum permitted forces and torques that the pump can absorb can be
found in the Chapter headed "Technical Description" under "Permitted
load on supports".
The suction and delivery pipes should be supported in such a way that the
weight of the pipe is not transferred to the centrifugal pump.
Page 60 of 117
4.5.3
Aligning the coupling
Data on the coupling used (tolerances, application limits, aligning information,
etc.) can be found in the manufacturer's operating instructions.
/CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER
DOCUMENTATION/COUPLING)
5
1
Fig. 4-5
4
3
Electronic aligning
Item
Component
1
2
Hub - pump side
Hub - motor side
3
Spacer sleeve
2
5
Fig. 4-6
Item
4
5
Conventional aligning
Component
Flexible part
Coupling aligning device
The coupling must be aligned with a suitable device.
The tolerances observed when aligning the coupling are to be recorded in
the erection work report on the coupling.
After the coupling has been set, it must be fitted with a coupling guard
according to the regulations issued by the authorities.
Page 61 of 117
Suction pipe
The following must be observed at the suction pipe:






The suction pipe should be kept as short as possible to maintain pipe
friction losses at a minimum.
Run a pressure test to check the pipe for leaks.
The suction pipe should rise or fall slightly towards the centrifugal
pump,
If a reducing piece is installed directly upstream of the centrifugal
pump, the narrowing section thereof should always be at the bottom
(Fig. 4-7).
Inlet points in the suction pipe should be located at a distance from the
centrifugal pump suction flange that is equivalent to a minimum of 5
times the diameter of the suction pipe.
For safety reasons the pump must be prevented from starting up while
it is opened. (lockable maintenance switch or main switch)
Cleaning opening with
cover
Suction branch
(Special accessories)
Fig. 4-7 suction pipe
After connecting up the suction and delivery pipes stress-free, check
alignment of the unit and rotate the impeller by hand.
4.6
Instruments


According to the manufacturers' instructions, the sealing water
monitoring unit is to be connected to the sealing water system and to
the connections provided at the centrifugal pump.
Special accessories (temperature monitoring, vibration measurements,
etc.) are to be connected up to the centrifugal pump according to the
manufacturer's instructions. Please contact Andritz AG if you have
special requirements.
Page 62 of 117
4.7
Electrical equipment
Motor and instruments are to be connected up according to the operating
instructions provided by the appropriate supplier.
/CENTRIFUGAL PUMP ACPxxxx/ SUPPLIER DOCUMENTATION/...
The electrical equipment must be installed such that there is no risk of
injury to personnel, nor of damage to machines. All regulations in this
respect must be observed.
Earthing
In addition to protective earthing, the following measures must be
observed to protect machine components:

Shielded power cables (3-core) with separate protective earth cable for
frequency converter drives. The shield for high frequency is to be
applied to the motor and to the frequency converter.

All machine parts and frequency-inverter fed motors are to be
connected with earthing straps.

The non-drive side of the motor must have insulated bearings.

Frequency converter outlets are fitted with du/dt filters.

The regulations issued by the manufacturer of the frequency converter
must be observed.
Specified cable:
NYCWY for all frequency inverter drives.
NYCWY is used as power and control cable in all plants, buildings,
outdoors, underground, and in water. The use of NYCWY cables is
described in VDE 0298 Part 1, the current carrying capacity in HD 603 S1
and VDE 0276 Part 1000.
Design: Single or multi-wire conductors, with concentric, ceander-shaped,
non insulated copper wire, counter-coil made of copper strip under the
outer covering. PVC-core insulation, different core colors according to
VDE 0293, common core shielding, outer covering of PVC, standard color
black, flame retardant. Cable configuration according to
VDE 0295/IEC 60228.
Technical data:
Minimum bending radius . . . . . . . . . . . . . . . . . . . .12 x cable diameter
Temperature range
on installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5°C to +50°C
after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -40°C to +70°C
Nominal voltage (U0/U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6/1.0 kV Test
voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 kV
Identification code of core . . . . . . . . . . . . . . . . . . . . . . . . . . VDE 0293
Page 63 of 117
4.8
Cold test
Prerequisites
The following utilities must be available:

Electric power

Water
Lubrication

First filling of lubricant and recording of all further lubrication
procedures according to the section headed “Lubrication” in the
MAINTENANCE chapter.
Machine may be damaged if inappropriate oil or grease grades are
used as first filling.
CAUTION
Cold test
Only use oils or greases with the properties listed in the lubrication
schedules.
Cold test is to be carried out together with the customer’s authorized
representative.
The work steps listed in the cold test certificate shall be carried out for the
cold test, and documented.
/ATTACHMENT/CERTIFICATES AND BLOCK DIAGRAMS
The cold test should be performed according to the following table.
Step Activity
1
To avoid damage to the impeller and the shaft seal, check the
pump for any debris.
Check by rotating the pump manually through one complete
revolution before start-up.
2
Visual check on the pump, particularly the coupling guard, for
any deformations.
3
Check whether the bearings have been filled with lubricant.
Re-lubricate as described in the Chapter on "Maintenance".
4
Turn on the sealing water supply (tandem mechanical seal,
packing).
Page 64 of 117
Step Activity
5
Check direction of rotation without medium:
Remove the intermediate sleeve of the coupling (see section
4.5.3).
Switch the motor and off briefly in order to check the direction
of rotation.
The motor must rotate in the direction of the arrow provided on
the pump casing.
Lock out motor
Remove the intermediate sleeve of the coupling according to
section 4.5.3.
Mount coupling guard






Switch the motor on and off briefly in order to check the
direction of rotation.

6
7
8
Check
of rotation
with
• Thedirection
motor must
rotate in
themedium:
direction of the arrow provided
on the pump casing.

chest,
open suction and delivery valves
• Fill
Lock
out motor

Open sealing water pipe
• Remove the intermediate sleeve of the coupling according to

Switch
the5.5.3.
motor on and off briefly in order to check the
section
direction of rotation.
Mount
coupling
guard
 • The motor must rotate
in the
direction
of the arrow provided on
the pump casing.
Caution: Rotating parts, e.g. the coupling!
•
Mount coupling guard
Fill chest, open suction and delivery valves so that the pump is
filled with the medium.
Switch motor on and observe for a brief period to see whether
everything is running properly.
Final inspection
The customer and the erection work supervisor shall conduct a final
inspection of the installation on completion of the cold tests.
Certificates
The following certificates are issued after completion of the ISO cold test


Cold test certificate
Certificate of completion of erection work.
Page 65 of 117
5
START-UP
5.1
General
Initial start-up of the centrifugal pump shall be prepared and carried out by
the Contractor or by ANDRITZ AG personnel. Start-up takes place in
accordance with the start-up sequence plan and ANDRITZ AG’s start-up
routines.
Practical training at the machine should also be provided during start-up.
Participants must receive instruction on the theory beforehand.
5.2
Safety regulations
DANGER
General safety
instructions
Start-up shall be carried out under the control of ANDRITZ AG’s start-up
supervisor or by the Buyer.
Qualification of
assigned personnel
Start-up may only be carried out by trained, skilled workers.
Personal protective
apparel
start-up and erection work:

Hard hat

Protective shoes

Goggles

Gloves must be worn when handling aggressive media such as oil,
cleaning agent, chemicals, lubricants, white water, etc.
Page 66 of 117
5.3
Prerequisites for start-up
The following must be checked before start-up:
Motor may be started up unintentionally.
Risk to life and limb and risk of damaging the machine or its DANGER
components.
DANGER
Check for leaks
Take care that the motor cannot be started up!
The pump and pipework must be leak proof before start-up.
Leaks, particularly in the suction pipe, can reduce performance of the
pump substantially and interfere with filling of the pump before start-up.
Parts of the pump which are under pressure are not considered pressure
vessels in terms of the official regulations on pressure vessels.
Sense of rotation of
motor
Before start-up check that the motor is rotating in the right direction.
Before checking the sense of rotation of the motor, it is essential to
remove the coupling spacer.
CAUTION
Free rotation
The motor must rotate in the direction of the arrow provided on the
motor casing.
The pump must be able to rotate freely. Here the two coupling halves
should be separated from one another.
By rotating the pump end coupling half the operator can check whether the
shaft can be rotated freely.
Page 67 of 117
Aligning the
coupling
A further check should be performed to ensure that the coupling is properly
aligned. Coupling alignment should then be verified in writing.
For assembly and disassembly of the coupling, as well as the tolerances to
be observed here, please see:
/CENTRIFUGAL PUMP/SUPPLIER DOCUMENTATION/COUPLING
Pump lubrication
Before start-up, check the lubricant (oil or grease) to be used for the pump
and the drive bearing.
Due to the pump not being lubricated correctly!
DANGER
The pump should never be operated without a suitable lubricant!
If the pump is kept in storage for a longer period before being put into
operation, dirt and water may enter the pump kin the meantime. If there are
substantial fluctuations in temperature, there may be some condensation.
Shaft seal and
sealing water
Some parameters must be checked in order to ensure that the box
mechanical seal is functioning well.




Only clean water from an external source should be used.
The maximum particle size of 80 microns must not be exceeded.
The maximum solids content of 2 mg/l (ppm) must not be exceeded.
The stuffing box mechanical seal must have an adequate supply of
sealing water. Throughput 3-5 l/min
Page 68 of 117
5.4
Start-up
CAUTION
Starting up the
centrifugal pump
Machine may be damaged by inappropriate starting.
All electric interlocks must be functional and checked.
If all preliminary requirements (see Chapter 5.3) have been fulfilled, the
pump can then be started up according to the following table:
Prerequisites
1
Suction pipe and pump casing must be filled with the medium.
2
The pump casing must be vented with the vent screw (903.5)
3
The shaft seal must have an adequate supply of sealing water.
4
6
There must be sufficient sealing water escaping from the stuffing
box (30-80 drops/min).
The mechanical seal must have a supply of sealing water. The
flow of sealing water should only be throttled at the outlet.
The valve in the suction pipe is fully open.
7
The valve in the delivery pipe is completely closed.
5
8
Start up pump and open the delivery side valve far enough to
obtain the desired flow rate.
9
Check stuffing box to see whether enough liquid is coming out. If
not, the stuffing box gland must be slackened right away. If the
packing material still becomes too hot after the gland has been
slackened, the operator must shut down the pump and look for
the cause of the problem.
When the stuffing box has been running for approx. 10 minutes
without any problems, it can then be tightened again moderately.
To set the stuffing box, see Chapter on “Maintenance”.
Tab. 5-1 Starting up the centrifugal pump
DANGER
If the pump runs dry!
The pump should never be allowed to run dry under any
circumstances, not even briefly.
Page 69 of 117
Fist trial run
Functioning of the pump must be monitored carefully during the first few
Hours in operation.
Particular attention must be paid to the following:

Temperature of the shaft seal

Required amount of sealing water to the shaft seal

Bearing temperature and vibration

Pressure and flow rate in the pump
If there are any unusual noises, it is essential to look for the cause
without delay and then eliminate the problem!
CAUTION
After start-up, the centrifugal pump is handed over to the mill operator in a
complete, reliable condition and ready for operation.
5.5
Certificates
The following certificates must be completed and signed after start-up:

Start-up certificate:

Provisional acceptance certificate:
Page 70 of 117
6
OPERATION
6.1
General
This chapter describes the activities required for starting, operating and
stopping the centrifugal pump. Possible malfunctions and troubleshooting
methods are also presented.
6.2
Safety regulations
DANGER
General safety
instructions
Qualification of
assigned personnel
The equipment may only be operated by qualified personnel.
Operating personnel must know where the emergency-off switches and the
escape routes are located.
Operating the centrifugal pump is not permitted without all the required
safety devices
Operating personnel must have been instructed in the function and possible
failure of machine monitoring equipment, and in carrying out maintenance
and inspection work (shift log book, maintenance inspection records).
Personal Protective
apparel
The following personal protective equipment/apparel shall be used when
performing work on the machine (e.g. troubleshooting):

Hard hat

Protective gloves

Protective shoes

Goggles
Page 71 of 117
6.3
Control via DCS
The centrifugal pump can be started up and operated entirely from the DCS.
There is no permanent workspace provided at the pump.
6.4
Starting
Prerequisites
All preliminary requirements for start-up must be fulfilled before switching
on the pump.
See: “Start-up” chapter
Before starting the centrifugal pump, the following parameters must
be fulfilled:

The valve in the suction pipe must be fully open..

Suction pipe and pump casing must be filled with the medium to be
pumped.
If the pump runs dry!
DANGER
The pump should never be allowed to run dry under any
circumstances, not even briefly.


CAUTION
The shaft seal must have an adequate supply of sealing water. Sealing
water quantities: see chapter headed “Description”.
With stuffing box seals, there must be sufficient sealing water escaping
from the stuffing box. (30-80 drops/min)
Immediately after starting up the pump, open the valve in the delivery
pipe far enough to obtain the desired flow rate.
The required flow rate must always be set using the valve on the
delivery side!
If the operating pressure (see instruments) is not obtained within a
short time, the pump must be stopped again and the cause of the
problem found!
Page 72 of 117
Automatic starting
When using the group start, all of the steps required are implemented
automatically by the DCS.
Manual start
Carry out the following steps for manual start.
Step
1
2
3
Activity
Open suction-side valve
Switch on motor
Open delivery-side valve
Tab. 6-1 Manual start
6.5
Checks after initial start-up
The following items must be checked after initial start-up:
CAUTION

Temperature of the shaft seal

Required amount of sealing water and required sealing water
pressure to the shaft seal

Bearing temperature and vibration

Pressure and flow rate in the pump
If there are any unusual noises, it is essential to look for the cause
without delay and then eliminate the problem!
Page 73 of 117
6.6
Normal operation
Do not operate without all safety devices ON.
DANGER
While the pump is in operation the operating personnel should record the
relevant data (shift record and data sheets).
Activities during normal operations
Once per shift
The following work has to be performed per shift in normal operation.
Component
Centrifugal pump, complete
Activity
Visual check (sealing water, etc.)
Tab. 6-2 Activities to be performed in every shift
Page 74 of 117
6.7
Centrifugal pump requirements (delivery head and flow
rate)
Sizing
The pump sizing (delivery head/flow rate0 refers to the values shown on
the pump’s type plate.
The values obtainable for head and flow rate can be read off the impeller
diameter and the defined operating speed is shown in the performance
diagram.
If the impeller diameter or speed of the pump is changed, the duty point
moves to a different performance curve for head and flow rate.
Performance
change during
operation
The power consumption point on the curve can be changed by opening or
closing the valve in the delivery pipe further or by altering the pump speed.
Do not operate the pump with the valves closed as this may cause
damage to the pump!
CAUTION
Changing the
Operating
parameters
Too low NPSH plant value can cause damage to the impeller!
If the operating parameters for which the pump has been sized are
changed, the following considerations should also be taken into account:





All parameters for the pump (pressure, impeller diameter…) were sized
for the original duty point. These factors should be fully checked for the
new operating conditions.
The centrifugal pump can be operated for a short time with the delivery
valve closed. For continuous operation, however, a minimum flow rate
is required. The curve shown in the performance diagram for the
required suction pressure (set NPSH pump begins at the point of the
permitted continuous minimum flow rate.
The inlet characteristics of the system (actual NPSH plant), as well as the
drive motor and shaft outputs, must always be checked under changed
operating conditions.
The efficiency of the pump is the deciding factor in its overall service
life, thus the power requirement of the pump must be checked.
The performance diagram is based on values with clean water. If other
liquids are pumped, the data on delivery head and flow rate, as well as
power requirement, may change. These factors were taken into account
when the pump was originally selected and should also be considered
in the light of any new operating conditions.
Page 75 of 117
6.8
Shutdown
Automatic
shutdown
When using the group stop, all necessary steps are carried out
automatically with the DCS.
Brief manual
shutdown
Carry out the following steps to shut the centrifugal pump down manually
for a brief period:


Stop the pump motor
Close the valve in the delivery pipe if necessary
Do not switch on the motor during reverse motion by the pump!
CAUTION
Manual shutdown,
e.g. for service
purposes
Carry out the following steps to shut the centrifugal pump down manually
for a longer period:






Stop the pump motor
Close the valve in the delivery pipe
Close the valve in the suction pipe
Relieve the pressure in the pump and drain it
Flush the pump out if aggressive media are pumped
Close sealing water feed
If there is a danger of the pump liquid freezing, the pump and pipe
should be emptied!
CAUTION
Page 76 of 117
6.9
Operating malfunctions and troubleshooting
Malfunction
Pump is not pumping
medium
Insufficient delivery head
Possible cause
Insufficient pre-filling of pump
Steam bubbles forming in
suction pipe (NPSH plant)
Pressure difference between
inlet pressure and steam
pressure is too low
Air entering the suction pipe,
suction port or shaft seal
Suction pipe, suction valve or
impeller are clogged
Speed too low
Flow resistance in the pipe is
greater than the delivery head
generated at the pump
Unexpected air/gas content in
pumping medium
Unexpectedly high viscosity in
the medium
Speed too low
Wrong direction of rotation
Pump parts coming into
contact with pressure are worn,
damaged or clogged
Delivery-side valve partly open
or closed
Remedy
Repeat pre-filling of the pump
and suction pipe
Check the suction pipe
Check the suction pipe and the
shaft seal
entire pump for clogging
Check the speed requirements
Check the resistance in the
pipe
Contact Andritz AG for further
instructions
instructions
Change sense of rotation of the
motor
Check and minimize the pipe
resistance
Check the pump and change
any worn or damaged parts if
necessary
Open valve
Tab. 6-3 Operating malfunctions and troubleshooting
Page 77 of 117
Malfunction
Inadequate or
irregular flow rate
High power loss
Possible cause
Steam bubbles forming in the
suction pipe
Net positive suction height (NPSH
plant ) is too low
Pressure difference between NPSH
plant and NPSH pump is too low
Air inlet in the suction pipe, suction
port or shaft seal
pumping medium
Unexpectedly high viscosity in the
medium
Pump parts coming into contact
with pressure are worn, damaged
or clogged
Bearing damaged
Speed too high
Unexpected specific gravitation in
pumping medium
Unexpectedly high viscosity in the
medium
Pump shaft bent or running off
center
Rotating objects or pump parts
causing friction in the pump
Pump parts coming into contact
with pressure are worn, damaged
or clogged
Remedy
Repeat pre-filling of the pump and
suction pipe
Change sense of rotation of the motor
Check whether the suction valve is fully
open and the suction pipe clear
Check the suction pipe and the shaft
seal
instructions
instructions
Check the suction pipe and the entire
pump for clogging
Check the resistance in the pipe
Check the pump and change any worn
or damaged parts if necessary
Disassemble the pump and change the
bearings
Check the motor speed
Check the sense of rotation of the
motor
instructions
instructions
Replace the pump shaft and bearing
Disassemble and check the inside of
the pump
Check the pump and change any worn
or damaged parts if necessary
Page 78 of 117
Malfunction
Excessive noise and/or
vibration
Possible cause
NPSH plant and NPSH pump is
too low
pumping medium
Air inlet in the suction pipe,
suction port or shaft seal
Speed too low
The pump flow rate is below
the permitted minimum level
(cavitation)
The foundation is too weak
Pump is subjected to
additional load if the pipe is
not adequately supported
Pump and motor are not in
true alignment
Broken or eccentric pump
shaft
Rotating objects or pump
parts causing friction in the
pump
Pump parts coming into
contact with pressure are
worn damaged or clogged
Bearing worn or loose
Insufficient or excessive
lubrication
Impeller damaged or
unbalanced
Remedy
instructions
shaft seal
Check the requirements of the
pump system
Reinforce the foundation
Check pipe support
Check pump/motor alignment or
re-align
Replace the pump shaft and
bearing
Disassemble and check the
inside of the pump
Check the pump and change any
worn or damaged parts if
necessary
Disassemble the pump and
replace the bearings if necessary
Check that pump has appropriate
lubrication
Disassemble the pump and
replace the impeller if necessary
Page 79 of 117
Malfunction
Excessive wear on
bearing
Pump
overheating/jamming
Possible cause
Remedy
Pump and motor are not in true
alignment
re-align
Broken or eccentric pump shaft
Impeller damaged or
unbalanced
Insufficient or excessive
lubrication
Bearing not installed properly or
dirty
the pump
Disassemble the pump and replace
the impeller if necessary
Check that pump has appropriate
lubrication
Replace bearing assembly if
necessary and check the lubricating
system for contamination
Mount new original bearing
Wrong bearing or not the
original bearing mounted in the
pump
Delivery-side valve closed
Insufficient pre-filling of pump
NPSH plant and NPSH pump is too
low
The pump flow rate is below the
permitted minimum level
(cavitation)
Pump and motor are not in true
alignment
Bearing worn or loose
Broken or eccentric pump shaft
Impeller damaged or
unbalanced
Open valve
Repeat pre-filling of the pump and
suction pipe
Check the requirements of the pump
system
re-align
the bearings if necessary
the impeller if necessary
the pump
Check and minimize the pipe
resistance
Page 80 of 117
7
MAINTENANCE
7.1
General
This chapter describes the maintenance and upkeep of the centrifugal pump,
which is the responsibility of the machine/mill operator.
All activities mentioned in this chapter must be performed at the correct time.
The ANDRITZ AG service department is at your disposal for troubleshooting,
as well as for extensive maintenance and repair work. (/CENTRIFUGAL
PUMP/INTRODUCTION)
Workers trained and authorized by Andritz AG may also carry out repairs on
site after obtaining consent from AAG.
7.2
Safety regulations
DANGER
General safety
Instructions
Sufficient spaced for maintenance work must be included right away in the
arrangement drawing.
Maintenance and upkeep must not be performed when the machine is in
operation, all feed pipes must be closed beforehand.
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads against falling down.
Do not step or walk below suspended loads. Standing below suspended
loads is dangerous and thus forbidden.
If chemicals are used it is crucial to flush out the pump before starting
maintenance work in order to avoid chemical burns.
Use only genuine spare parts.
It is forbidden to repair leaks and defects by plugging, hammering, painting
or impregnating!
Energy supply
Before beginning any maintenance or repair work the operator must
disconnect the energy supply to all drives securely. This can be achieved
with a maintenance switch, lockable racks in the MCC, or with other
suitable measures that comply with the safety regulations.
Qualification of
assigned personnel
Maintenance and upkeep must be carried out by trained and skilled
personnel.
Work on the electrical equipment must be carried out without exception by
skilled electricians.
Page 81 of 117
Personal protective
apparel
cleaning and maintenance:




Lighting
7.3
Hard hat
Protective gloves
Protective shoes
Goggles
The operator shall ensure that adequate lighting is provided (with extra-low
voltage bulbs) during service and repair work.
Regular maintenance
CAUTION
Regular monitoring of operations and performance of the centrifugal
pump will allow the operator to detect any need for maintenance and
repairs in good time. This guarantees a high level of efficiency, a
trouble-free operating sequence, and minimizes the maintenance
costs!
The discharge pressure, flow rate and power consumption should be
monitored continuously.
For machines operating continuously (24 hours/day, 7 days/week), a
prescheduled maintenance period every two weeks is recommended.
During these periods the machine should be shut down, thoroughly
cleaned and checked for wear.
Machines operating less than 24 hours per day should be subjected to
these routine checks and cleaned at each stoppage.
General machine
Checks
The following checks should be made when the machine is at a standstill:
Component
Checks
Shaft seal
Leaks and wear
Bearing
Lubricant quantity (oil level)
Static seals
Leaks
Coupling
Wear on the coupling pads
Complete pump
Visual check
Tab. 7-1 General machine checks
Page 82 of 117
In the course of general machine checks all additional units should also be
checked to guarantee that the entire plant functions satisfactorily. For these
checks, the attached manufacturer’s maintenance and upkeep instructions
must be observed.
/FANPUMP/SUPPLIER DOCUMENTATION
Malfunctions and unforeseen modifications found during these checks must
be eliminated immediately
Cleaning
Clean the impeller by hosing down or brushing when at standstill.
Contact with the pulp may cause skin damage and burning.
Persons handling the pulp should not suffer from an allergic condition
to such substances.
WARNING
Personal protective apparel must be worn.
Do not use caustic agents fro cleaning.
Make sure no water, steam or other cleaning medium enters electrical
plant components.
CAUTION
Page 83 of 117
7.4
Maintenance schedule
In addition to the work outlined below, maintenance and word required for
normal operations (/CENTRIFUGAL PUMP/OPERATION/NORMAL
OPEATION) must also be carried out.
Monthly
The following maintenance work is to be carried out at monthly intervals.
Component
Bearings
Volute casing (upper part –
lower part)
Shaft with bearing
Coupling
Activity

Check temperature

Measure vibrations

Oil level Grease level is to be checked

Check for strange noises

Check for corrosion and wear



Stuffing box seal
Mechanical seal
Pipework
Complete pump





Check for smooth running
Check alignment
Check pads for wear
Check for leaks
Check for wear
Check for leaks
Check for leaks
Cleaning
Tab. 7-2 Monthly maintenance work
6-monthly
Annually
The following maintenance work is to be carried out at 6-monthly intervals
Component
Activity
Complete pump

Motor

Check mounting of pump on the
foundation
Check mounting of motor on the
foundation
Tab. 7-3 -monthly maintenance work
The following maintenance work is to be carried out at annual intervals.
Component
Complete pump
Activity

Complete service according to
instructions form Andritz AG
(Oil change Grease change, impeller
check, etc.)
Tab. 7-4 Annual maintenance work
Page 84 of 117
7.5
Fasteners
Screw material
Bolts and screws are manufactured in several classes of material. The
heads of these screws and bolts are marked to identify the strength class
of the screw or bolt. Damaged or lost fasters should only be replaced with
fasteners of the same material.
Check
Unless they are suitably tightened, screws can work loose or fail under
operating conditions. In the course of maintenance work, all fastening
screws must be checked.


Tighten
During the first six months:
After the first six months:
every 2 to 21/2 months
semi-annually
During checks and maintenance work it is imperative to tighten all
fastening screws to the torque specified for each screw in the drawings or
in the table below.
Pre-stressing forces and tightening torques in the table apply to normal
screw connections. Please contact Andritz AG in the event of special
requirements.
The thread and screw head should be lubricated with an appropriate
lubricant (for example Molyslide Plus from Loctite).
Tab. 7-5 Tightening Torques and Pre-stressing Forces for Rigid Screws(Normal thread)
Page 85 of 117
Wrong torque tightening may cause machine damage and hazards
leading to personal injury.
CAUTION
The above pre-stressing forces and tightening torques must be
observed.
Page 86 of 117
7.6
Lubrication
7.6.1
Oil lubrication
During works assembly the bearings and the oil chamber are filled
with a preserving oil providing protection for approximately 6
months.
CAUTION
Before start-up, oil must be filled up to the middle of the oil inspection
glass according to the table (Tab.7-6)
There is no need to remove the preserving oil.
Lubricating oil brands
Lubricating oils
Viscosity:
64 cST at 40°C (ISO VG68)
Manufacturer
Tab.7-6
warning
CAUTION
Type
BP
BP Energol HLP 68
Esso
Teresso 68
Mobil
D.T.E. Heavy Medium
Shell
Shell Tellus Oil S 68
Castrol
Hyspin AWS 68
Lubricating oil brands
If the surface temperature of the bearing housing rises above 800C,
Andritz AG should be consulted.
Bearing damage may be caused by using the wrong oil!
Use only grades according to Tab.8-6.
Do not mix different brands or grades of oil.
Page 87 of 117
Oil change
The first oil change should be carried out after approximately 200 operating
hours. After this oil changes should be performed according to Tab. 8-7.
Pump speed (n)
1000-1800 rpm
3000-3600 rpm
Oil change interval
Annually
6-monthly
Tab. 7-7 Oil change intervals
The oil should be changed at operating temperature.
The oil change should be performed according to the following table.
Step
1
2
3
4
Activity
Open hexagon head screw plug (903.1).and drain the used oil
off into a container (suitable size for the oil quantity).
Screw in hexagon head plug screws (903.1) again with a new
seal (411.1).
Dispose of used oil according to the appropriate regulations.
Fill in the fresh oil at the vent screw (672).up to the middle of
the oil level glass (642).
Tab. 7-8 Change oil
672
642
411.1,
903.1
Fig. 7-1 Bearing housing – oil lubrication
Page 88 of 117
Oil quantities
The following oil quantities are required, depending on the pump size:
Bearing size
BS42
BS48
BS60
BS75
BS100
Pump type
ACP 100-250
ACP 125-250
ACP 65-315
ACP 100-315
ACP 125-315
ACP 150-315
ACP 125-400
ACP 150-400
ACP 100-500
ACP 200-400
ACP 300-400
ACP 150-500
ACP 200-500
ACP 450-550
ACP 300-700
ACP 400-700
ACP 600-700
Oil quantity (litres)
1
1.7
2.5
6.6
8
Tab. 7-8 Oil quantities
The oil level may drop during operation. If an oil level controller is installed,
this too must be filled with oil.
Page 89 of 117
7.6.2
Grease lubrication
The bearings are filled with grease during works assembly.
The bearings should be topped up with approx. 2 to 10 g of grease
before being put into operation.
WARNING
Grease types
The following lubricating greases should be used for operating conditions at
which the surface temperature of the bearing housing is less than +80˚C.
Manufacturer
Type
Exxon
Mobil
EXXON Beacon 2
Mobilux EP2
Shell
SHELL Alvania R3
Shell
SHELL Alvania G3
SKF
SKF LGMT2
FAG
FAG Arcand L71V
Tab.7-9 Grease type
If the surface temperature of the bearing housing rises above +80˚C
Andritz AG should be consulted.
WARNING
Lubrication
The bearings should be re-greased according to the following table.
Re-lubrication interval1)(hour)
Bearing housing temperature<600C
Impeller Coupling Impeller Coupling
740
980
1480
2950
side
side
side
side
rpm
rpm
rpm
rpm
BS42
85
55
25
15
14000
1000
6500
2500
BS48
135
85
30
20
12000
8000
6000
2000
BS60
230
150
40
25
10000
7500
5000
BS75
300
180
50
30
10000
7500
5000
BS100
500
300
75
55
8500
6000
4000
1)
Each 150C increase in the surface temperature reduces the lubricating interval by half
Tab. 7-10 Lubrication schedule
Bearing
First lubrication (g)
Re-lubrication (g)
Bearing damage may be caused by incorrect lubrication.
Different grades of grease should not be mixed.
CAUTION
Use only oil grades according to Tab.7-9.
Page 90 of 117
Grease change
The old grease should be cleaned off the bearing housing after
approximately 24,000 operating hours. Then fill the bearing with fresh
grease.
The grease in the bearings is to be changed according to the `following
table.
672
636.1
636.2
903.2
411.2
903.1
411.1
Fig. 7-2 Grease lubricating at the bearing
Step
1
2
3
4
Activity
Remove the screwed drain plug (903.1)
Extract the old grease by suction through the bore holes
(903.1).
Use a suction device with a flexible suction pipe to
extract the grease.
Insert the screwed drain plug (903.1) with. new sealing
rings(411.1).
Top up with fresh grease at the grease nipples (636.1/2)
.
Grease grade and quantity are should in the
Tables(Tab.7-9,Tab.7-9)
Tab. 7-10 Grease change
Page 91 of 117
7.7
Aligning the coupling
The coupling alignment must be checked after each of the following
assembly steps and corrected if necessary.






In particular:
After mounting and before grouting in the pump
After grouting in
After installing the pipe work
After the trial run with water
When the bearing support is replaced by a new bearing support
If the alignment changes during production, the pump can also be aligned
at operating temperature.
The coupling must be aligned as described in the chapter on “Erection
work”
Aligning tolerances
Permitted tolerances
/CENTRIFUGAL PUMP/SUPPLIER DOCUMENTATION/COUPLING
Check
The coupling pads should be checked at least every 4000 to 6000
operating hours.
Page 92 of 117
7.8
Installing and removing the pull-out unit
Preparations
The following parts must be prepared before starting to disassemble the
pull-out unit:




Tools
Lifting gear
Belts, ropes
Replacement parts
The pump must be thoroughly cleaned before carrying out any
maintenance work.
Complete the following work before starting to remove the unit itself:
Step
1
2
3
4
Activity
Shut down all drives at all poles an secure against accidental
start..
Remove the hoses leading to the shaft seal.
Remove coupling guard (681),
Remove the intermediate coupling piece after loosening the
screws.
Tab.7-11 Activities before removal
Limbs can be trapped or crushed during disassembly work.
Wear your personal protective apparel.
DANGER
Page 93 of 117
7.8.1
Removing the pull-out unit
The pull-out unit comprises the complete bearing support (330), casing
cover (161), the shaft seal (430), and impeller (230).
Remove the pull-out unit according to the following table:
Step
1
2
3
Activity
Detach bolts (920.3) connecting to the spiral casing (102).
Detach bolts (901.3) connecting to supporting leg (183).
Attach lifting slings according to Fig. 7-3:

Through the bearing support windows

Between the coupling half and the bearing housing (350)

Secure sling to lifting hook and tension slightly.
Caution: Take care to maintain the balance
Push the pull-out unit out with the forcing screws (901.2).
Set the pull-out unit down in the assembly area.
4
5
Tab.7-12. Removing the pull-out unit
Fig.7-3 Lifting the pull-out unit
Page 94 of 117
7.8.2
Mounting the pull-out unit
Install the pull-out unit according to the following table:
Step
1
2
3
4
5
6
7
8
9
Activity
Check the impeller (230) and the front lining (135) visually
for any defects.
Rotate the shaft manually through a complete revolution and
check that it is running smoothly.
Replace O-ring (412.1) and grease lightly with silicone grease.
Turn forcing screws (901.2) back.
Attach lifting sling according to Tab. 7-12.
Install pull-out unit in the spiral casing (102) and secure with
the nuts (920.1).
Screw in support leg bolts (901.3) and tighten.
Rotate pump manually through a complete revolution and
check that it rotates freely and smoothly. If the pump does not
rotate smoothly, check the gap between the impeller (230)
and the front lining (135).
Mount the coupling reduction sleeve (840) and check the
alignment.
Mount coupling guard (681) and sealing guard..
10
Tab.7-12. Removing the pull-out unit
Page 95 of 117
7.9
Changing the impeller and the front lining
GEFAHR
Danger of injury at the impeller!
Impellers may have very sharp edges, particularly when they are
worn.
Wear protective clothing and gloves!
Limbs can be trapped or crushed during disassembly work!
Wear your personal protective apparel!
GEFAHR
Proceed according to the following table when changing the impeller (230)
and the front lining (135).:
Step
1
2
3
4
5
6
7
8
Procedure
Switch off pump (according to Chapter on "Operation").
Remove pull-out unit according to Section 7.8.1.
Open locking plate (931) and impeller nut (901.4).
Pull off impeller (230) by pushing it off the casing cover (161).
Detach bolts (920.2) at the front lining (135).
Push front lining out with forcing screws.
Set up pull-out unit vertically with the impeller side up
Mount new impeller (230) so that there is a gap of
0.5-1.5mm (according to impeller diameter) between the
casing cover (161) and the vanes on the back of the
impeller.
This gap is obtained by inserting spacers (551.2) of
various thicknesses (0.3 - 1.0 mm).
9
Mount new lock washer (931), tighten impeller nut (901.4)
and secure.
Screw stud bolts (902.2) into the lining and mount the
required spacers.
Turn back forcing screws and mount front lining in
spiral casing (102).
Tighten bolts with torque wrench.
The gap between impeller (230) and front lining (135) should
be 03~0.6mm.
Mount pull-out unit according to Section 7.8.2.
Start up pump according to Chapter on "Operation".
10
11
Tab. 7-13 Changing the impeller and the front lining
Page 96 of 117
1
2
Fig. 7-4 Gaps according to impeller diameter
Page 97 of 117
102
412.2
161
412.1
902.2
135
230
931
901.4
551.2
Fig. 7-5 Impeller and location of gaps
Page 98 of 117
7.10
Trimming the impeller
The various pump service data are obtained with different impeller
diameters. The required diameter for various service data can be found in
the pump characteristic diagram or in the data sheet. Before changing an
impeller, it must be turned down to the required impeller diameter first of
all.
When trimming down the impeller vanes, proceed according to the
following table:
Step
1
2
3
4
Procedure
Use spare impeller (always has full diameter and is
balanced).
Determine the required diameter from the documentation
or the new diameter from the characteristic curve.
Mark the new diameter on the vane, mill down to the
impeller base (leave impeller base with full diameter) and
debar.
Impellers for speed n=3000rpm and impellers with full
diameter greater than 400mm must be statically
rebalanced.
Tab. 7-15 Turning the impeller
Page 99 of 117
7.11
Changing the shaft seals
7.11.1
Changing the Andritz cartridge mechanical seal-single and double
To avoid greater damage the mechanical seal must be replaced
immediately if there is leakage on the atmospheric side.
The pump must always be shut down under the following conditions in
order to avoid serious damage:




DANGER
Sealing water leaking on the atmospheric side
Abnormal consumption of sealing water
Drop in sealing water pressure
Conveying medium in the sealing water
If hot and aggressive pumping medium leaks, this may cause a risk to
life and limb and damage to the machine or its components. The
machine should only be disassembled by qualified and authorized
personnel.
Change the mechanical seal (433.1) according to the following table:
Step
1
2
3
4
5
6
7
8
9
10
11
Procedure
Shut down pump according to Chapter on “Operation”.
Remove impeller as Section 7.9.
Loosen screws (914.1)
Remove cartridge (433.1) by means of forcing screws.
CAUTION: Take care not to lose the spacer plates (551.2)
Inspect seal and try to find the reason for the fault (dry
running, wear, etc.). if necessary, consult specialists at the
seal supplier company.
Clean all parts and mount a new seal.
Secure cartridge in casing cover (161) with the screws (914.1)
Mount spacers (551.2) and impeller (230).
Check gap between impeller back vanes and the casing cover
(161). As Section 7.9.
Mount impeller according to Section 7.9.
Start up pump according to Chapter on “Operation”.
Tab. 7-16 Changing the Andritz cartridge mechanical seal – single and double
Page 100 of 117
433.1
551.2
Medium
Atmosphere
914.1
161
Fig. 7-6 Changing the Andritz cartridge mechanical seal - single
551.2
433.1
Atmosphere
Medium
914.1
161
Fig. 7-7 Changing the Andritz cartridge mechanical seal - double
Page 101 of 117
7.11.2
Changing the standard cartridge mechanical seal-single and
double




DANGER
life and limb and damage to the machine or its components.
Step Procedure
1
2
3
4
Loosen nuts (920.4)
Separate cartridge1) (433.1) and adapter (145).
CAUTION: Take care not to lose the spacer plates (551.2 and
504)
5
Loosen nuts (920.1), remove casing cover (161) by means of
forcing screws.
6
Take the seal (433.1) out of pump shaft, Inspect seal and try
to find the reason for the fault (dry running, wear, etc.). If
necessary, consult specialists at the seal supplier company.
6
Clean all parts and change a new seal.
7
Assemble the new seal and casing cover in reverse order.
8
Mount spacers (504 and 551.2) and impeller (230).
9
10
11
1)
Different cartridge seal may have different mounting and dismounting way, please see
the individual instruction.
Tab. 7-17 Changing the Standard cartridge mechanical seal – single and double
Page 102 of 117
920.4
504
551.2
433.1
Medium
Atmosphere
145
161
Fig. 7-8 Changing the Standard cartridge mechanical seal - single
920.4
504
551.2
433.1
Medium
Atmosphere
145
161
Fig. 7-9 Changing the Standard cartridge mechanical seal - double
Page 103 of 117
7.11.3
Changing the single standard mechanical seal
DANGER
Step
1
2
3
4
5
6
7
9
10
11
Procedure
Loosen screws (914.12)1)
Remove seal (433.1)
CAUTION: Take care not to lose the spacer plates (551.2 and
504 )2)
running, wear, etc.). If necessary, consult specialists at the
Clean all parts and assemble a new seal in reverse order..
Mount spacers (551.2 and 504)2) and impeller (230).
1)
only type A3 SR6 seal has 914.14
2)
type A1 MG12 seal no need 504
Tab. 7-18 Changing the Single standard mechanical seal
Page 104 of 117
504
551.2
Type: A1
433.1
Type: A2
Medium
Atmosphere
551.2
433.1
Type: A3
Medium
Atmosphere
914.12
Fig. 7-10 Changing the Single standard mechanical seal
Page 105 of 117
7.11.4
Changing the tandem standard mechanical seal




DANGER
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
1)
Procedure
Remove mechanical seal (433.1) on medium side according
to section 8.11.3.
Loosen screws (914.2)，pull back the sealing casing (441)
Loosen nuts (920.1), remove casing cover (161) by means of
forcing screws.
Loosen screws (904), remove set collar (506)1),
Remove mechanical seal (433.2)
running, wear, etc.). If necessary, consult specialists at the
Clean all parts and assemble two new seals in reverse order..
Mount spacers (551.2 and 504)2) and impeller (230).
only type B3 seal has not 506;
2)
type B1 seal no need 504
Tab. 7-19 Changing the Tandem standard mechanical seal
Page 106 of 117
504
551.2
914.2
441
Type: B1
904
433.1
Type: B2
433.2
506
904
Medium
Atmosphere
914.2
441
904
Type: B3
433.1
Medium
433.2
412.6
Atmosphere
Fig. 7-11 Changing the Tandem standard mechanical seal
Page 107 of 117
7.11.5
Changing the stuffing box packing and the shaft protection sleeve
The stuffing box packing is a wear part. When the stuffing box gland (452)
is approximately 5mm from the parallel surface of the stuffing box casing
(451), the packing must be changed.
Removing the
stuffing box
packing
When changing the stuffing box packing (461) and shaft protection sleeve
(524), proceed according to the following table:
Step
1
2
3
4
5
6
7
8
9
Procedure
Loosen nuts (920.4) and pull back the stuffing box gland(452)
Remove old stuffing box packing (461) and pull out of the
sealing water ring (458).
Clean the stuffing box gland, sealing water ring and packing
area thoroughly.
Check shaft protection sleeve (524) and replace if worn.
Notches or grooves on the surface of the shaft protection
sleeve cause excessive wear on the stuffing box packing!
Remove spacers (551.2) and shaft protection sleeve (524).
Lubricate new original shaft protection sleeve (524) with new
o-ring (912.6) using special grease and push onto the shaft up
to the shaft collar.
Tab. 7-18 Changing the stuffing box packing
Page 108 of 117
412.6
452
452
452
452 920.4
551.2
912.6
524
461
428
451
Fig. 7-12 Changing the Stuffing box packing
Page 109 of 117
Installing the
stuffing box
packing
Proceed according to the following table when installing the packing:
Step
1
2
3
4
5
6
7
8
Procedure
Mark packing (see Fig.8-17) and cut to the appropriate length.
Keep stuffing box clean, do not stretch or squash stuffing box
when measuring and cutting.
Wrap the packing round the shaft protection sleeve, then push
the first packing ring into the stuffing box, starting at the butt
joint.
The ends of the ring must form a butt joint with no gap.
Push the first packing rings right in using a suitable tool.
Install the remaining packing rings and the sealing water ring
(458). Mount the remaining packing rings with the butt joints
offset by 120 degrees.
When the stuffing box gland (452) has been installed, tighten
all screws evenly according to the following setting guidelines.
Tab. 7-19 Installing the stuffing box packing
Flush joint, no gap
Packing cord
Packing marking
Fig. 7-13 Marking packing stuffing box packing
Page 110 of 117
Setting the stuffing
box
The following settings must be observed:

Never tighten the stuffing box gland so far that drainage of sealing
water is brought to a complete halt.
At least a few drops should drain off per minute in order to avoid
excessive friction and wear on the shaft.

Set the stuffing box such that the shaft protection sleeve at the stuffing
box gland is always moist.

The stuffing box should be checked every 15 minutes during the first
few hours in operation.

The stuffing box should leak excessively at start-up and be adjusted for
a normal slow leak after the running-in period (approx. 12 hrs)...

Loosen the screw at the stuffing box gland if the stuffing box overheats.

Do not tighten gland nuts more than 1/6 of a turn in 15 minutes running
time.
The stuffing box will be damaged if the stuffing box gland is screwed
too tight.
CAUTION
Only use the tools intended for this purpose!
Page 111 of 117
7.12
Changing the anti-friction bearings
The anti-friction bearings are designed for continuous operation under full
load for approximately 50000 operating hours. Higher bearing temperature
and vibration at the bearing support are a sign of impending bearing
damage. If these symptoms occur, the bearing must be changed.
Change the anti-bearings according to the following table:
Step
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1)
Grease lubrication;
Tab. 7-20
Procedure
Remove impeller according to Section 7.9.
Dismount shaft seal according to Section 7.11.
Remove bearing cover (360), splash ring (507.1/2)1),
splash ring washer (550.1/2)1), radial seals (421.1/2)1),
bearing isolator (423.1/2)2).
Dismount shaft(211), including anti-friction bearing
parts(321.1/2), locking plate (931.1) and locking nut
(923), oil splash ring (508)
Remove the bearing parts on the shaft.
Clean the parts to be re-used and prepare new parts
(anti-bearings, radial seals, splash ring, bearing isolator)
Install the angular contact ball bearings (321.1)onto the
shaft by heating (approx.800C), tighten the inner rings of
the angular contact ball bearings using the locking plate
(931.1) and locking nut (923),
Install the oil splash ring (508)
Install the deep groove ball bearing (321.2) onto the shaft
by hearing (approx.800C)
Install the bearing housing vertically with the pump side
upwards.
Raise shaft vertically on the pump side with ring bolt and
from above by turning into the bearing housing.
Mount bearing cover (360), with new O-ring (412.1), and
new splash ring (507.1/2)1), new splash ring washer
(550.1/2)1), new radial seals (421.1/2)1), new bearing
isolator (423.1/2)2).
Check shaft by rotating in manually.
Re-install the bearing support in reverse order.
2)
Oil lubrication
Changing the anti-friction bearings
Page 112 of 117
321.1
360
636.1 412.1
508
931.1
321.2 636.2 550.1, 421.1, 507.1
550.1
421.1
507.1
211
904.2
923
904.1
Fig. 7-14 Bearing support-Grease lubrication
903.3, 411.3
903.4, 411.4
423.2
423.1
914.10
411.10
914.11
411.11
Fig. 7-15 Bearing support-Oil lubrication
Page 113 of 117
7.13
Disassembly and disposal
DANGER
The machine must be disconnected from the power source before
disassembly!
The machine should only be disassembled by qualified and
authorized personnel.
If the machine/plant is to be shut down, the following must be taken into
account for subsequent disposal:
Machine parts
• The machine components must be disassembled according to the
various materials, lubricant fillings and various forms of contamination.
• The materials must be disposed of in accordance with the applicable
legislation on waste disposal.
• Proof must be brought of the properties and the disposal route of
various materials according to the applicable regulations on proof
recovery and disposal (e.g. statement and entry in register).
Plastic parts
WARNING
Additives
• Limitations due to the material used
• Limitations due to contact with the process water (contamination)
• Limitations due to contact with the ambient air (contamination)
Compile the necessary documents before disposal and dispose of the
materials according to the regulations, observing the documents.
Plastic parts are flammable.
Observe the local fire protection regulations. When separating the
materials, do not work with welding devices or equipment that
sparks.
Oil, utilities and cleaning agents must also be disposed of according to
the local provisions and in compliance with the appropriate
manufacturer regulations.
Page 114 of 117
Other metal
groups to be
separated are:
• Surface-treated sheet steel, such as powder-coated or wet-painted
covers, etc.
• Surface-coated construction steel, such as rotating parts, gratings,
bolts, etc.
• Copper (electrical grade copper or silver-coated electrical grade
copper), such as bush bars, connecting straps, connections pieces, etc.
• Cables
• Built-in units
Page 115 of 117
8
TECHNICAL DATA
8.1
Data sheet
8.2
Characteristic curve
8.3
Dimensional drawing
Page 116 of 117
SUPPLIER
DOCUMENTATION
8.4
Coupling
8.5
Shaft seal
Page 117 of 117

Centrifugal Pump, ACP series

Transcription

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