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PumpWorks 610 PWD, Installation, Operation And Maintenance Instructions, Page: 3 / 28

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PumpWorks 610 PWD Installation, Operation And Maintenance Instructions Download Page 3

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3

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28

 

 

Model: PWD  Rev. B_12/2/2015

  

TABLE OF CONTENTS 

INTRODUCTION 

Company Details ........................................................................................................................................ 4 
Declaration of Conformity ........................................................................................................................... 5 
Scope ................. .......................................................................................................................................6 
Description ................................................................................................................................................. 6 
General ....................................................................................................................................................... 6 
Safety ...................................................................................................................................................... 6-9 
CE and ATEX marking and approvals ..................................................................................................... 10 
Disclaimer................................................................................................................................................. 10 
Copyright .................................................................................................................................................. 10 
Design Performance ................................................................................................................................ 10 
Duty Conditions ................................................................................................................................... 10-11 
Specific Gravity ........................................................................................................................................ 11 
Speed ....................................................................................................................................................... 11 
NPSH ....................................................................................................................................................... 11 

 

INSTALLATION 

Receiving Inspection ................................................................................................................................ 11 
Short Term Storage ............................................................................................................................. 11-12 
Long Term Storage .................................................................................................................................. 12 

Foundation ......................................................................................................................................... 12-1

3

 

Leveling .................................................................................................................................................... 13 
Grouting .................................................................................................................................................... 13 
Piping Recommendations ................................................................................................................... 13-14 
Lifting ........................................................................................................................................................ 14 
Pump Installation ................................................................................................................................. 14-15 
Driver Installation ..................................................................................................................................... 15 
Alignment ............................................................................................................................................ 15-16 
Couplings ................................................................................................................................................. 16 

Lubrication .......................................................................................................................................... 16-

18

 

Recommended Control Settings ............................................................................................................. 

19

 

Pre-Startup Procedures ..................................................................................................................... 19-2

0

 

Startup Procedures .................................................................................................................................. 20 
Startup Inspection .................................................................................................................................... 20 
Shutdown ................................................................................................................................................. 21 
Extended Shutdown ................................................................................................................................. 21 

 

MAINTENANCE 

Preventative Maintenance ................................................................................................................... 21-22 
Mechanical Seal / Bearing Housing Removal ..................................................................................... 22-26 
Rotating Element Removal ................................................................................................................. 26-27

 

 

TROUBLESHOOTING 

Troubleshooting .................................................................................................................................. 28-29 

 

REVISIONS 

Revisions .................................................................................................................................................. 29 
 

Summary of Contents for PWD

Page 1: ......

Page 2: ...Page 2 of 28 Model PWD Rev B_12 2 2015 INSTALLATION OPERATION MAINTANENCE Model PWD ...

Page 3: ...1 Short Term Storage 11 12 Long Term Storage 12 Foundation 12 13 Leveling 13 Grouting 13 Piping Recommendations 13 14 Lifting 14 Pump Installation 14 15 Driver Installation 15 Alignment 15 16 Couplings 16 Lubrication 16 18 Recommended Control Settings 19 Pre Startup Procedures 19 20 Startup Procedures 20 Startup Inspection 20 Shutdown 21 Extended Shutdown 21 MAINTENANCE Preventative Maintenance 21...

Page 4: ...PI 610 ISO 13709 pumps for petroleum refinery gas processing oil processing petrochemical hydrocarbon and crude oil pipeline offshore installations platform and aviation jet fueling MARKING OF MACHINERY All machinery is marked visibly with the business name and full address of the manufacturer Model Size ATEX Marking Serial number The year construction was completed ...

Page 5: ...formation is s information pr applies only to on of Inc aration 10 x 13HE 8 ES DARDS 13709 2009 A 13463 1 2009 PRESSURE V N 8 AND SEC T3 2460 retains eclaration of C the Applicable and specifica ure on this doc nt have been a s contained in t rior to installing the equipment corporat of Conf STAGE API 610 Sept 2 EN 13463 5 2 VESSEL CODE CTION 9 NACE 7 s a copy of the Conformity co e Internationa a...

Page 6: ... to facilitate its permitted mpliance with help ensure risks The account loca observed by uld result in or delays rical hazards ns will involve loss of life ger warnings mpliance of safety could me risk to safe r h e e s s d d The the c this m P phys prop obse Ope P injury Pum e e n T hous e d h e e l regu obse prod oper requ laws y n s e s f d e oper dam toxic woul loss atmo in sa the h explo uni...

Page 7: ...me due to a nal protective ers company ng around this ts additiona nt may be t d y s d r g y s d t d d w e a pum cons or pr guar safet the r elect arisin mac or ve to pr dB A noise shou Impa rusty e y s l e use the certif Neve p for whic sulting PumpW Neve roper lubricat Never oper rds in place Never oper ty devices ins Avoid all elec risks of electr Always trical acciden Be aware ng from con hine...

Page 8: ... injury or includes any e of parts not If there is a d us of the mpWorks 610 y identifies mbling units to Trapped lt in a violent pply heat to ng devices to stated in this s damaged or ay cause an ration of toxic environmenta HILE WORK of the casing nd post weld ing and hand s l regu RK IS STA y n s s y s e l r y t a e 0 s d t o o s r n c l dam putti witho Pum area place retre fall o good rated Ar...

Page 9: ...rface of 1 8 If the ONS AND T uirements for ally explosive be carried out pWorks 610 ules apply to res the risks of and physica apor or both oved products National ot be held ntrained and GS AND A machinery and ertain regions he applicable r s e e disas disco insta s o r train explo appl URE OF DU t d n a s g e e build shut proc follow I utiliz and T avail purc TRAINING r e t o f l h s d d unau in...

Page 10: ... properly select install or use authorized PumpWorks 610 parts and accessories is considered misuse Damage or failure caused by misuse is not covered by PumpWorks 610 s warranty In addition any modification of PumpWorks 610 products or removal of original components may impair the safety of these products in their use COPYWRIGHT All rights reserved No part of these instructions may be reproduced s...

Page 11: ...uld be consulted to ensure that no loss of components has occurred during shipment Any loss or damage should be immediately reported to the carrier and a representative of PumpWorks 610 SHORT TERM STORAGE Unless specifically designated by contract for long term storage this unit has setup for short term storage for a period not more than 6 months from date of manufacture When the pump is received ...

Page 12: ...Royal Purple VP 10 or equivalent vapor phase rust inhibitor Mark the coupling or shaft with a distinct marking at 0 90 180 and 270 degrees When marking is complete set the element with 0 at top center This for a reference for rotating the element to prevent permanent sag set in the shaft due to the weight of the element The element will need to be routinely rotated as specified below Do not spin t...

Page 13: ...o ensure that there is no twist or bow between the driver and pump pads Once leveled snug the anchor bolts down Do not tighten completely until grout is applied and cured GROUTING PumpWorks 610 standard epoxy primer is compatible with Escoweld 7505E 7530 Epoxy Grout The grout manufacturers detailed instructions on site preparation and installation of the product should be followed The anchors and ...

Page 14: ...equate for lifting Magnetically centered rotors should be secured to prevent movement of the rotor and subsequent damage to the sleeve bearings The rotors are normally secured with a bracket on the drive end shaft extension For the lifting of the complete skidded package lifting lugs are provided on the skid which per API are capable of lifting the entire package A spreader bar is recommended for ...

Page 15: ...the longevity of your equipment Although reverse indicator alignment and rim and face indicator alignments can produce satisfactory results PumpWorks 610 strongly advises that laser alignment equipment be utilized for the alignment of this equipment Alignments should be performed by qualified and experienced personnel It is up to the end user to ensure that all safety procedures especially lock ou...

Page 16: ...has clearance over the top of the key as to not prevent hub makeup on the shaft taper fit LUBRICATION Several methods of providing lubrication to bearings are employed in pump lube systems The type of bearings used in the pump and design specifications dictate which type of system is used The three primary lube systems are Pressurized lube system This system involves an external lube oil pump with...

Page 17: ...her cast into the housing or marked on an oil level tag which is attached to the housing If the tag is missing refer to factory supplied documentation This oil level dimension is from the shaft centerline to the level of the oil in the bearing housing which also correlates to the top of the star nuts If it is necessary to adjust the star nuts loosen and adjust to the proper height and secure the b...

Page 18: ...due to moisture heat and contaminates Excessive deterioration of the oil could cause damage and premature failure of the bearings and bearing journals Oil levels should be checked on a weekly basis during normal operations and replenished as required Sampling of the oil is highly recommended to ensure the oil quality A pump shut down for more than 3 weeks should have the bearing lubricated prior t...

Page 19: ...URES been properly o the proper bolting freely seals are set have been been checked d that the e motor was on for the been properly ring housings er level of oil constant leve oiler on the n See Figure fitted pumps nd not bound n be done by plugs and ugh to verify ry oil systems proper oil fil checked for at exchanger ETTINGS e e e e e e ALA VIBR I u p a a y r n d e s e y s l e e d y d y s l r r 9...

Page 20: ...gins to develop pressure start slowly opening the discharge valve Avoid making any abrupt change in discharge velocity in order to prevent surging within the piping Surging can cause serious damage to the internals of the pump The pump should reach discharge pressure as soon as it reaches operating speed If does not happen shut the pump down immediately Re vent and prime the pump and try re starti...

Page 21: ...ned The schedule listed below is suggested only as a minimum The preventative maintenance program you establish should be based on the equipment s usage service and history As an indicator of the pump s performance and overall health the end user should use the following Performance Monitoring Vibration Monitoring Temperature Monitoring Oil Analysis A baseline of performance should be established ...

Page 22: ...ks610 are made for replacement of the mechanical seals without disturbing the pump or driver For this purpose packages are supplied by PumpWorks610 and in compliance with API 610 specifications with a spacer coupling to allow clearance for seal removal The following procedures are given as a customer reference only and do not necessarily cover every step of removal for every configuration of const...

Page 23: ... suction discharge and bypass valves have been closed and secured Drain fluids from pump and bearing housing that is to be removed Use proper precautions for hazardous or flammable liquids Remove constant oiler globes Refer to applicable MSDS sheets as necessary 2 Remove coupling guard as necessary for rotating shaft 3 Remove RTD probes as applicable 4 Remove fan shroud and fan as applicable 5 Rem...

Page 24: ...ng startup of the unit monitor seals for leaks and take corrective actions if leaks occur SLEEVE BALL THRUST BEARING HOUSING OUTBOARD A Follow all Lockout Tag Out Procedures prior to removal of guards and maintenance of unit a Ensure ALL electrical sources have be de energized and locked out b Ensure suction discharge and bypass valves have been closed and secured c Drain fluids from pump and bear...

Page 25: ... outboard positions Inspect and replace as necessary 10 Back off set screws as necessary in thrust bearing nut Remove thrust bearing retaining nut Thrust bearing nuts come off the direction the unit turns Pull thrust disc Do not loose shim between the thrust disc and shaft shoulder This shim is used to center the rotating assembly to the internal components Failure to re install this shim could re...

Page 26: ...ationary wear parts and volutes and checked for TIR 10 To set centering use a magnetic base dial indicator on one end of the pump and set the indicator parallel to the shaft axis Using a screw driver or small pry bar between an impeller and the shroud wall carefully push the element all the way toward the dial indicator Set the indicator to 0 Carefully push the element in the opposite direction an...

Page 27: ...rrect performance in regards flange connections or stuffing as required to flow and head boxes b Excessive running clearances Replace worn parts as required c NPSH available too low Verify suction valve is fully open and there are no obstructions such as clogged suction strainer d Broken impeller shroud Repair or replace as required Bearing temperature too a Not enough lubricant or cooling Verify ...

Page 28: ...orn or damaged bearings Replace or repair as necessary f Piping connected to the pump Correct as required Consult not properly supported factory if in doubt Motor runs hot a Not enough NPSH causing the Consult the factory for re rating demand on the pump to be too information high b Viscosity change has been made Consult the factory for re rating thereby exceeding the motor information rating c Mo...

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