PUMPIRAN CPKN Installation & Operating Manual Download

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Standardised

Chemical Pump

Installation

Operating Manual

Bearings UP02 to UP06 and P08s

CPKN

Summary of Contents for CPKN

Page 1: ...Standardised Chemical Pump Installation Operating Manual Bearings UP02 to UP06 and P08s CPKN ...

Page 2: ...2 Contents Contents Legal information Installation Operating Manual CPKN Original operating manual subject to technical modification without prior notice ...

Page 3: ...s Safety information for the operator user Safety information for maintenance inspection and installation work Unauthorised modes of operation Explosion protection Transport Temporary Storage Disposal Transport Storage and preservation Return to supplier Disposal Description of the Pump Set General description Designation Name plate Design details Design and function Noise characteristics Scope of...

Page 4: ...n of rotation Commissioning Start up Shutdown Commissioning start up Operating limits Shutdown storage preservation Returning to service after storage Servicing Maintenance Safety regulations Servicing inspection Drainage disposal Dismantling the pump set Reassembling the pump set Tightening torques Spare parts stock Trouble shooting Related Documents General assembly drawing with list of componen...

Page 5: ...cate of decontamination certifies that the pump set has been properly drained to eliminate any environmental and health hazards arising from components in contact with the fluid handled Complete pump set consisting of pump drive additional components and accessories The line which is connected to the suction nozzle The line which is connected to the discharge nozzle The part of the pump in which t...

Page 6: ...ialist technical personnel Section 2 4 Page9 1 4 Other applicable documents Table 1 Overview of other applicable documents 1 General Document Contents Data sheet Description of the technical data of the pump set General arrangement drawing Outline drawing Description of mating and installation dimensions for the pump set Drawing of auxiliary connections Description of auxiliary connections Hydraul...

Page 7: ...7 Symbol Description 1 2 Step by step instructions Note Recommendations and important information on how to handle the product Symbol 1 General ...

Page 8: ...t must only be operated within the operating limits which are described in the other applicable documents Only operate pumps pump sets which are in perfect technical condition Do not operate partially assembled pumps pump sets DANGER Symbol Description DANGER DANGER This signal word indicates a high risk hazard which if not avoided will result in death or serious injury WARNING WARNING This signal...

Page 9: ...ed to install operate maintain and inspect the machinery this manual refers to The responsibilities competence and supervision of all personnel involved in installation operation maintenance and inspection must be clearly defined by the operator Deficits in knowledge must be rectified by sufficiently trained specialist personnel training and instructing the personnel who will carry out the respect...

Page 10: ... familiar with the manual Carry out work on the pump set during standstill only The pump casing must have cooled down to ambient temperature Pump pressure must have been released and the pump must have been drained When taking the pump set out of service always adhere to the procedure described in the manual Section 6 1 12 Page 37 Decontaminate pumps which handle fluids posing a health hazard Sect...

Page 11: ...ture classes and the resulting theoretical temperature limits of the fluid handled a possible temperature rise in the shaft seal area has already been taken into account The temperature class specifies the maximum permissible temperature at the surface of the pump set during operation For the permissible operating temperature of the pump in question refer to the data sheet Table 4 Temperature limi...

Page 12: ...g limits The minimum flows indicated in Section 6 2 3 Page 38 refer to water and water like fluids Longer operating periods with these fluids and at the flow rates indicated will not cause an additionalincreaseinthetemperaturesatthepumpsurface However ifthephysicalproperties of the fluids handled are different from water it is essential to check whether an additional heat build up may occur and if...

Page 13: ...ition Never attach the suspension arrangement to the free shaft end or the motor eyebolt Refer to the weights given in the general arrangement drawing Observe the local accident prevention regulations Use suitable permitted lifting tackle e g self tightening lifting tongs CAUTION Damage during storage by humidity dirt or vermin Corrosion contamination of the pump set For outdoor storage cover the ...

Page 14: ...m where the atmospheric humidity is as constant as possible Rotate the shaft by hand once a month e g via the motor fan If properly stored indoors the pump set is protected for a maximum of 12 months New pumps pump sets are supplied by our factory duly prepared for storage For storing a pump set which has already been operated observe the instructions in Section 6 3 1 Page 39 3 3 Return to supplie...

Page 15: ...g pump Horizontal installation Back pull out design Single stage Meets technical requirements to ISO 5199 2002 Dimensions and ratings to EN 22 858 ISO 2858 complemented by pumps of nominal diameters DN 25 DN 200 and above Pump casing Single or double volute depending on the pump size Radially split volute casing Volute casing with integrally cast pump feet Volute casing partly with casing wear rin...

Page 16: ... with different shaft seals examples Bearings Motor end bearing Fixed bearing Paired angular contact ball bearing Axial movement of the rotor limited to maximum 0 5 mm Oil lubrication Optional grease lubrication Conversion from stuffing box packing to mechanical seal and vice versa is possible without any rework on the casing cover by using the relevant replacement parts Illustration Type of seal ...

Page 17: ...nction Bearing bracket designation Bearings used Code Description UP Bearing bracket 03 Size code based on dimensions of seal chamber and shaft end Bearing bracket Rolling element bearing Pump end Motor end UP02 NU307 2 x 7307 B G UP03 NU311 2 x 7311 B G 8 UP04 NU311 2 x 7311 B G 8 UP05 NU313 2 x 7313 B G 8 UP06 NU416 2 x 7319 B G P08s NU416 2 x 7319 B G designation F A G designation SKF designati...

Page 18: ...g element bearings 9 and 10 which are supported by a bearing bracket 5 linked with the pump casing and or casing cover The pump is sealed by a shaft seal Standardised mechanical seal or stuffing box packing 4 6 Noise characteristics Table 10 Surface sound pressure level LpA3 4 Design Function Sealing Rated power input PN kW Pump Pump set 2900 rpm dB 1450 rpm dB 960 rpm 760 rpm dB 2900 rpm dB 1450 ...

Page 19: ... spacer Coupling guard to EN 294 Baseplate to ISO 3661 cast or welded for pump and motor in torsion resistant design Channel section steel or folded steel plate As required 4 8 Dimensions and weights For dimensions and weights please refer to the general arrangement drawing outline drawing of the pump set Drive Shaft coupling Contact guard Baseplate Special accessories 4 Description of the Pump Se...

Page 20: ...y and damage to property Make sure the foundation concrete is of sufficient strength min X0 to DIN 1045 Only place the pump set on a foundation whose concrete has set firmly Only place the pump set on a horizontal and level surface Refer to the weights given in the general arrangement drawing 1 Check the structural requirements All structural work required must have been prepared in accordance wit...

Page 21: ...t firmly then align the baseplate 6 Tighten the foundation bolts 4 evenly and firmly 7 Grout the baseplate using low shrinkage concrete with a standard particle size and a water cement ratio of 0 5 Produce flowability with the help of a solvent Perform secondary treatment of the concrete to DIN 1045 The installation surface has the required strength and characteristics 1 Position the pump set on t...

Page 22: ...owever such elements must not obstruct proper drainage or hinder disassembly of the unit The suction lift line suction head line has been laid with a rising downward slope towards the pump The nominal diameters of the pipelines are at least equal to the nominal diameters of the pump nozzles To prevent excessive pressure losses adapters to larger diameters have a diffuser angle of approximately 8 T...

Page 23: ...lter in the piping 5 4 2 Permissible forces and moments at the pump nozzles 4 Connect the pump nozzles with the piping The data on forces and moments apply to static pipelines only If the limits are exceeded they must be checked and verified If a computerised strength analysis is required please contact PUMPIRAN The values are only applicable if the pump is installed on a completely grouted basepl...

Page 24: ...200 3950 6200 2100 1500 1900 3050 2100 1500 1900 3050 5000 4500 4050 7850 4500 4050 5000 7850 2500 1750 2050 3650 2500 1750 2050 3650 6700 6000 5400 10450 6000 5400 6700 10450 3250 2300 2650 4800 3250 2300 2650 4800 8350 7450 6750 1305 7450 6750 8350 13050 4450 3150 3650 6550 4450 3150 3650 6550 10000 8950 8050 15650 8950 8050 10000 15650 6050 4300 4950 8900 6050 4300 4950 8900 32 125 32 160 32 20...

Page 25: ...fficiently vented Never close or cover the perforation of the bearing bracket guards e g by insulation WAR NING The volute casing and casing discharge cover take on the same temperature as the fluid handled Risk of burns Insulate the volute casing Fit protective equipment CAUTION Heat build up in the bearing bracket Never insulate the bearing bracket bearing bracket lantern and casing cover Explos...

Page 26: ...2 Place the straight edge axially on both coupling halves 3 Leave the straight edge in this position and turn the coupling by hand The coupling is correctly aligned if the distances A and B to the respective shafts are the same at all points around the circumference The radial and axial deviation of both coupling halves must not exceed 0 1 mm during standstill as well as at operating temperature a...

Page 27: ...otor with levelling screw The coupling guard and step guard if any have been removed 1 Check the coupling alignment 2 Unscrew the hexagon head bolts 1 at the motor and the locknuts 3 at the baseplate 3 Turn the levelling screws 2 by hand or by means of an open jawed wrench until the coupling alignment is correct 4 Re tighten the hexagon head bolts 1 at the motor and the locknuts 3 at the baseplate...

Page 28: ...or protection switch DANGE R Work on the pump set by unqualified personnel Danger of death from electric shock Always have the electrical connections installed by a trained electrician Observe regulations IEC 30364 DIN VDE 0100 and for explosion proof pump sets IEC 60079 DIN VDE 0165 1 1 Shim Fig 12 Pump set with shim 5 8 Electrical connection The coupling guard and step guard if any have been rem...

Page 29: ...oo long Damage to the pump set Keep switch over intervals between star and delta as short as possible see table Time relay settings for star delta starting Y time to be set Motor rating 30 kW 3 s 30 kW 5 s NOTE In compliance with DIN VDE 0530 Part 8 three phase motors are always wired for clockwise rotation looking at the motor shaft stub The pump s direction of rotation is indicated by an arrow o...

Page 30: ...ed interchange any two phases to correct the direction of rotation CAUTION CAUTION The correct direction of rotation of motor and pump is clockwise seen from the motor end 1 Start the motor and stop it again immediately to determine the motor s direction of rotation 2 Check the direction of rotation The motor s direction of rotation must match the arrow indicating the direction of rotation on the ...

Page 31: ...earings have been packed with grease at the factory Fill the bearing bracket with lubricating oil Oil quality see Section 7 2 3 1 2 Page 44 Oil quantity see Section 7 2 3 1 3 Page 44 Filling the constant level oiler with lubricating oil oil lubricated bearings only The constant level oiler is screwed into the upper tapping hole of the bearing bracket Grease lubricated bearings Oil lubricated beari...

Page 32: ...or reassembly Section 7 5 3 Page 51 If applicable fill the reservoir of non pressurised external fluid in accordance with the general arrangementdrawing Prior to starting up the pump apply barrier pressure as specified in the general arrangement drawing Apply the quantities and pressures specified in the data sheet and the general arrangement drawing 6 1 4 Priming and venting the pump NOTE An exce...

Page 33: ...th regard to mechanical corrosion Inlet temperature tE 10 to 30 C Outlet temperature tA maximum 45 C 6 1 6Water cooling 6 1 7 Cooling of the shaft seal Table 13 Cooling of the shaft seal5 CAUTION Deposit forming aggressive cooling water Damage to the pump Observe the cooling water quality CAUTION Vaporisation pressure of fluid handled higher than atmospheric pressure Damage to the shaft seal pump ...

Page 34: ...bserve the permissible temperature classes Section 2 10 2 Page 11 CAUTION Lack of heating medium Damage to the pump Provide sufficient quantities of a suitable heating medium CAUTION Time for warming up the pump too short Damage to the pump Check that the pump is sufficiently warmed up throughout CAUTION Impermissibly high temperature of the heating medium Fluid or heating medium could escape Obse...

Page 35: ...ture limits will be exceeded if the pump is operated with the suction and discharge lines closed Explosion hazard Leakage of hot or toxic fluids Never operate the pump with the shut off elements in the suction line and or discharge line closed Only start up the pump set with the discharge side gate valve slightly or fully open DANGE R Excessive temperatures due to dry running or excessive gas cont...

Page 36: ...the pump has been primed The leakage can be reduced 1 Tighten the nuts of the stuffing box gland by 1 6 turn 2 Monitor the leakage for another five minutes Excessive leakage Repeat steps 1 and 2 until the minimum value has been reached Not enough leakage Slightly loosen the nuts at the stuffing box gland No leakage Switch off the pump set immediately Loosen the stuffing box gland and repeat start ...

Page 37: ...th barrier fluid during standstill Only turn off the cooling liquid supply after the pump has cooled down NOTE If the discharge line is equipped with a non return or check valve the shut off element may remain open as long as there is some back pressure NOTE If shut off is not possible the pump will run in reverse direction The reverse runaway speed must be lower than the rated speed CAUTION Risk ...

Page 38: ...x 10 1 1xQopt 9 4 pole operation Qmax 10 1 25xQopt 9 The data refer to water and water like fluids Longer operating periods with these fluids and at the flow rates indicated will not cause an additional increase in the CAUTION Operation outside the permissible ambient temperature Damage to the pump set Observe the specified limits for permissible ambient temperatures Value Maximum 40 C Minimum See...

Page 39: ... Start up the pump set regularly between once a month and once every three months for approximately five minutes during prolonged shutdown periods This will prevent the formation of deposits within the pump and the pump intake area The pump set is removed from the pipe and stored The pump has been properly drained Section 7 3 Page 47 and the safety instructions for dismantling the pump have been o...

Page 40: ... information provided Section 3 Page13 6 4 Returning to service after storage Forreturningthepumptoserviceobservethesectionsoncommissioning start up Section 6 1 Page 31 and the operating limits Section 6 2 Page 37 In addition carry out all servicing maintenance operations before returning the pump set to service Section 7 Page 41 WAR NING Failure to re install or re activate protective devices Ris...

Page 41: ...NG Pump set started up inadvertently Risk of injury by moving parts Always make sure the electrical connections are disconnected before carrying out work on the pump set Make sure that the pump set cannot be started up accidentally WAR NING Fluids posing a health hazard or hot fluids Risk of personal injury Observe all relevant laws When draining the fluid take appropriate measures to protect pers...

Page 42: ...ings for running noises Vibrations noise and an increase in current input occurring during unchanged operating conditions indicate wear Monitor the correct functioning of any auxiliary connections Cooling system Take the pump out of service at least once a year to thoroughly clean the cooling system Monitor the stand by pump To make sure that the stand by pumps are ready for operation start them u...

Page 43: ...d Damage to the pump set Regularly check the coupling guard plastic components and other guards of rotating parts for deformation and sufficient distance from rotating parts Nominal diameter of the discharge nozzle up to DN 65 0 40 mm 0 1 0 60 mm 0 1 DN 80 to DN 200 0 5 mm 0 1 0 60 mm 0 1 DN 250 and above 0 65 mm 0 1 0 75 mm 0 1 Material 1 Material 2 If the clearances given are exceeded by more th...

Page 44: ...fter 300 operating hours After 300 operating hours After 300 operating hours After 8500 operating hours After 4200 operating hours After 2000 operating hours 70 C 80 C 80 C 90 C Designation Symbol to DIN 51502 Properties Lubricating oil to ISO VG 46 Kinematic viscosity at 40 C C C 46 4 mm s Flash point to Cleveland 175 Solidification point pour point 15 Application temperature12 Higher than permis...

Page 45: ...2 3 2 1 Intervals The bearings are re lubricated via the lubricating nipples see the following drawing 7 2 3 1 4 Changing the oil Fig 14 Bearing bracket with constant level oiler Fig 15 Position of lubricating nipples WAR NING Lubricants posing a health hazard Hazard to persons and the environment When draining the lubricant take appropriate measures to protect persons and the environment Observe ...

Page 46: ...ality 7 2 3 2 4 Changing the grease Table 23 Grease quality to DIN 51825 Table 24 Grease quantities for re lubrication and re filling 7 2 3 2 3 Grease quantities Soap basis NLGI grade W orked penetration at 25 C in mm 10 Drop point Temperature range Lithium 2 to 3 220 295 175 C 30 C to 120 C Bearings Re lubrication Pump end bearing Drive end bearing Bearing cover pump end Bearing cover drive end U...

Page 47: ... remove all auxiliary pipework 3 Remove the coupling guard 4 Remove the coupling spacer if any 7 3 Drainage disposal WAR NING Fluids posing a health hazard Hazardous to persons and the environment Collect and properly dispose of flushing liquid and any fluid residues Wear safety clothing and a protective mask if required Observe all legal regulations on the disposal of fluids posing a health hazar...

Page 48: ... nut 922 right hand thread 2 Remove impeller 230 with an impeller removal device 3 Place impeller 230 on a clean and level surface 4 Remove keys 940 1 from shaft 210 5 Remove and dispose of joint rings 411 7 4 6 Dismantling the shaft seal 7 4 6 1 Dismantling the mechanical seal cylindrical casing cover The notes and steps stated in Section 7 4 1 Page 47 to Section 7 4 5 Page 48 have been observed ...

Page 49: ...stuffing box ring 454 and drip plate 463 3 Remove casing cover 161 with O ring 412 and stuffing box packing 461 4 Remove stuffing box packing 461 and lantern ring 458 if any from the packing chamber 5 Pull off guard 680 6 Pull shaft protecting sleeve 524 and thrower 507 off shaft 210 7 4 7 Dismantling the bearings The notes and steps stated in Section 7 4 1 Page 47 to Section 7 4 6 Page 48 have be...

Page 50: ...e required after all use a commercially available contact adhesive e g Pattex Only apply adhesive at selected points and in thin layers Never use quick setting adhesives cyanoacrylate adhesives Coat the locating surfaces of the individual components and screwed connections with graphite or similar before reassembly For reassembly tighten all screws and bolts as specified in this manual Section 7 6...

Page 51: ...ase Grease lubrication Section 7 2 3 2 Page 45 16 Carefully push pre assembled shaft 210 with angular contact ball bearing 320 and the inner ring of cylindrical roller bearing 322 from the drive end into bearing bracket 330 17 Fit pump end bearing cover 360 01 with gasket 400 01 take care not to damage radial shaft seal ring 421 01 18 Fit motor end bearing cover 360 02 with gasket 400 02 take care...

Page 52: ... the rotating unit of mechanical seal 433 on shaft protecting sleeve 524 observe distance B see Supplementary Sheet of the mechanical seal 5 Slip pre assembled mechanical seal 433 and shaft protecting sleeve 524 onto shaft 210 Re installing the mechanical seal conical casing cover The notes and steps stated in Section 7 5 1 Page 50 to Section 7 5 2 Page 50 have been observed carried out The bearin...

Page 53: ...aft protecting sleeve 524 remains in the packing chamber 6 Insert stuffing box ring 454 with the drilled hole down 7 Fit stuffing box gland 452 and lightly fasten it by hand with the two hexagon nuts 920 02 support discs 550 8 Fit guard 680 9 Install complete discharge cover 161 with shaft protecting sleeve 524 in the pump take care not to damage joint ring 411 7 5 4 Fitting the Impeller The notes...

Page 54: ...new gasket 400 2 Tighten nut 920 01 at the volute casing 3 Fasten support foot 183 to the baseplate with a foundation bolt 7 5 6 Mounting the motor 1 Shift the motor to connect it to the pump via the coupling 2 Fasten the motor to the baseplate 3 Align the pump Section 5 7 Page 26 4 Connect the motor to the power supply refer to manufacturer s product literature 7 6Tightening torques 7 6 1Tighteni...

Page 55: ... 6 8 6 8 A4 70 A4 70 Stamp mark stud hex nut13 YK Y A4 70 A4 70 GA G Tightening torques Nm Bearing bracket lantern14 A B A B A B New threads15 15 16 20 16 New threads15 15 16 20 16 New threads15 15 16 20 16 M10 M12 M16 M20 8 8 8 8 30 25 5 24 47 30 39 9 25 5 37 6 24 _ _ _ 55 46 7 44 80 55 68 46 7 64 44 155 40 100 34 85 32 80 131 7 124 190 155 161 5 131 7 152 124 200 170 160 330 200 280 5 170 264 16...

Page 56: ...Shaft 1 1 1 2 2 2 20 230 Impeller 1 1 1 2 2 2 20 320 Angular contact ball bearing set 1 1 2 2 2 3 25 322 Cylindrical roller bearing Casing wear ring Shaft protecting sleeve 1 1 2 2 2 3 25 502 2 2 2 3 3 4 50 524 2 2 2 3 3 4 50 Gaskets for pump casing set 4 4 4 4 4 4 150 Torque transmitting coupling elements set 1 1 2 2 3 4 30 For variants with mechanical seal 433 Mechanical seal complete 1 1 2 2 2 ...

Page 57: ...2 2 2 2 2 100 200 5 6 2 2 2 2 5 12 2 2 2 2 2 2 2 2 2 2 9 8 3 2 2 2 7 9 3 3 3 3 3 3 3 3 3 3 80 315 65 315 9 9 3 2 2 2 7 12 3 3 3 3 3 3 3 3 3 3 80 400 10 10 3 2 2 2 8 27 3 3 3 3 3 3 3 3 3 3 100 250 8 8 3 2 2 2 6 13 3 3 3 3 3 3 3 3 3 3 100 315 9 9 3 2 2 2 7 14 3 3 3 3 3 3 3 3 3 3 100 400 10 10 3 2 2 2 8 14 3 3 3 3 3 3 3 3 3 3 125 250 8 9 3 2 2 2 6 15 3 3 3 3 3 3 3 3 3 3 125 315 9 10 3 2 2 2 7 16 3 3 ...

Page 58: ...rature Leakage at the pump Excessive leakage at the shaft seal Vibrations during pump operation Impermissible rise of temperature inside the pump Table 30 Trouble shooting A B C D E F G H 18 Pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure 19 Contact PUMPIRAN 8 Trouble shooting ...

Page 59: ... Fix the pipelines using anti vibration material X X Insufficient or excessive quantity of lubricant or unsuitable lubricant Top up reduce or change lubricant X Non compliance with specified coupling distance Correct distance according to the general arrangement drawing X X Motor is running on two phases only Replace the defective fuse Check the power cable connections X Rotor is out of balance Cl...

Page 60: ...60 9 Related Documents 9 1 General assembly drawing with list of components Fig 17 General assembly drawing of standard variant oil lubricated 9 Related Documents ...

Page 61: ...61 9 Related Documents Table 31 List of components ...

Page 62: ...chanical seal with cylindrical casing cover b 458 463 411 471 902 02 920 02 561 433 524 452 550 920 902 680 456 461 454 648 a b 636 360 01 400 01 636 320 400 02 932 01 932 02 550 322 360 02 550 550 914 02 507 914 01 421 01 931 920 421 02 Fig 19 Grease lubricated version ...

Page 63: ... directives as amended from time to time EC Machinery Directive 2006 42 EC The manufacturer also declares that the following harmonised international standards have been applied ISO 12100 1 A1 ISO 12100 2 A1 ISO 14121 1 EN 809 A1 Applied national technical standards and specifications in particular DIN EN ISO 5199 2002 10 EC Declaration of Conformity Manufacturer CPKN ...

Page 64: ...d inside and outside prior to dispatch placing at your disposal On seal less pumps the rotor has been removed from the pump for cleaning No special safety precautions are required for further handling The following safety precautions are required for flushing fluids fluid residues and disposal We confirm that the above data and information are correct and complete and that dispatch is effected in ...

Page 65: ...ating up 35 I Impeller type 16 Installation Installation on foundation 20 Installation without foundation 21 Installation at site 20 Intended use 8 Interchangeability of pump components 56 K Keeping the pump warm 35 M Maintenance repair 41 Mechanical seal 36 Misuse 9 Monitoring equipment 12 N Name plate 15 Noise characteristics 18 O Oil lubrication Intervals 44 Oil quality 44 Oil quantity 44 Opera...

Page 66: ...areness 9 Scope of supply 19 Shaft seal 16 Shutdown 37 40 Spare parts stock 56 Start up 35 Storage 14 40 T Temperature difference 35 Temperature limits 11 Tightening torques 54 55 Transport 13 Trouble shooting 59 W Water cooling 33 ...

Page 67: ...446 Marketing and Sale Office Tel 98 41 32890707 8 32890411 Fax 98 41 32872233 Sale Engineering Tel 98 41 32881286 Fax 98 41 32872233 Sale_eng pumpiran com Oil Gas Petrochemical Electro pumps Sales Office Tel 98 41 32891216 Fax 98 41 32888353 Oil Gas Petrochemical Electro pumps Sale Engineering Tel 98 41 32891216 Fax 98 41 32888353 Petro sale pumpiran com www pumpiran com 62060407 Publication Date...

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