Sulzer AHLSTAR 2.15 Series Installation,Operation And Maintenance Instruction Download Page 1

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ORIGINAL INSTRUCTION

SERIES 2.15

SPP id: 150201 / Replaces 141101 / en /

N32197

/ 5

AHLSTAR

PROCESS PUMPS

Installation, operation and maintenance instruction

Intended

use

Safety

instructions

Hoisting and transportation

Commissioning

Installation at the site

Operation
Preventive

maintenance

Corrective

maintenance

Spare parts recommendation

Summary of Contents for AHLSTAR 2.15 Series

Page 1: ...Replaces 141101 en N32197 5 AHLSTAR PROCESS PUMPS Installation operation and maintenance instruction Intended use Safety instructions Hoisting and transportation Commissioning Installation at the site Operation Preventive maintenance Corrective maintenance Spare parts recommendation ...

Page 2: ...ntenance instruction G ISO N32197 Cover Feb 15 G ISO Table of contents G ISO N31567 Intended use Nov 14 G ISO N31568 Safety instructions Feb 15 G N31569 Hoisting and transportation Jun 12 G N31570 Commissioning Sep 11 G ISO N31571 Installation at the site Nov 13 G ISO N31572 Operation Jun 12 G ISO N31573 Preventive maintenance Nov 14 G ISO N32198 Corrective maintenance Sep 14 G ISO N31575 Spare pa...

Page 3: ...INSTRUCTION SERIES 2 15 SPP id 141101 Replaces 140901 en N31567 4 AHLSTAR PROCESS PUMPS Intended use 1 General 2 Document identification 3 Type designation 4 Parts number designation 5 Nameplate designation 6 Capacity and head 7 Decommissioning ...

Page 4: ...data Sources Product scopes modules Product specification Product size Product specification and nameplate of the pump Other design alternatives impeller type and size materials lubrication flange drillings shaft sealing type etc Product specification Maximum allowable working pressure Product specification Dimensions pump accessories flanges etc Dimensional drawings Weights and mass moments of in...

Page 5: ... is required please contact our local representative for a quick supply of the information you need The enclosed instructions regarding a possible long term storage more than 3 months must be observed All customer instructions regarding this product and its main components are also available in an electronic format for viewing and printing depending on the end user s software hardware If electroni...

Page 6: ...ng unit SEUN 2 and bearing unit BEUN 3 The assembly is divided into the following modules sealing water equipment SWEQ 4 coupling unit COUN 5 and baseplate BAPL 6 The drive unit DRUN 0 is divided into two parts motor DRMO and frequency converter FRCO Documents are divided into two categories documents supplied with the delivery and documents supplied separately 4 2 Part numbers of parts connection...

Page 7: ...ive environments Fig 4 and Fig 5 Marking 1 Pump type 5 Speed of rotation rpm 2 Serial No Job No 6 Space for customer Pos No 3 Head m 7 Year of manufacture 4 Capacity flow l s Fig 1 Fig 2 MADE UNDER ONE OR MORE OF THE FOLLOWING US PATENTS NOS 4 863 353 4 594 052 OTHER PATENTS PENDING Fig 3 0123 II 2 G c T3 c The protection class used is constructional safety T3 Temperature class indicates the maxim...

Page 8: ...ve closed For continuous operation a minimum flow is still required The required suction head NPSH required curve presented in the characteristic curve always starts from the point of the minimum continuous flow allowed The suction properties of the system NPSH available and drive motor power are always to be checked in a new operating point The efficiency of a pump is a relevant factor when estim...

Page 9: ... use Packaging materials must be recycled or disposed of using methods which are acceptable in terms of environmental protection and which conform to local legislation and regulations Make sure that hazardous substances are disposed of safely and that the personnel use appropriate personal protective equipment Safety considerations must always meet the requirements of valid regulations ...

Page 10: ...s 140901 en N31568 8 AHLSTAR PROCESS PUMPS Safety instructions 1 General 2 Safety of machinery 3 Definitions 4 Essential safety aspects 5 Ignition hazard assessment 6 Safety signs affixed to the product 7 Operating situations affecting product safety 8 Balance and vibration 9 Wet end MAX 5 mm 0 2 in ...

Page 11: ...any other safety information issued by the plant operator The exact and detailed process and application data is relevant for the safe and reliable operation of the product Special environmental conditions at the place of installation should always be checked between the end user and manufacturer Such conditions are e g Abnormal temperature High humidity Corrosive atmospheres Pressure fluctuations...

Page 12: ...exposed within the danger zone and all operator groups of the machine must be specified jointly between the Customer and the Manufacturer for example for the purpose of introductory training arranged for the operators of the machine 2 2 1 2 Principles of safety integration As a machine manufacturer we have in accordance with the contents of the delivery followed the Machinery Directive and or the ...

Page 13: ...otected against all loading and stress The instructions concerning the purpose of the machine limitations of use allowable flange forces and support of piping supplied with the machine must be absolutely followed During operation there is always a risk of rupture in the piping connected to the machine risk of high pressure hot harmful liquid spray if the supplied instructions are violated 2 2 3 3 ...

Page 14: ...In these cases additional steps should be taken to eliminate any risk of injury caused by contact with or proximity to machinery parts Maintenance requires the heating of some parts prior to installation Carefulness is imperative during installation and appropriate personal protective equipment must be used during installation 2 2 4 5 Fire and explosion Exact and detailed information on the proces...

Page 15: ...pairing the machine principles of ergonomics avoiding excessive use of muscular power utilization of lifting gear lifting positions lighting of the area cleanliness etc must also be taken into account 2 2 5 2 Access to operating position and servicing points Where the location design for the machine is not included in the delivery steps must be taken to situate the machine at the point of operatio...

Page 16: ...or national legislation of the country where the machine is used 2 2 6 3 Marking and instructions The marking and instructions for the machine must be drawn up in accordance with the Machinery Directive and or national legislation of the country where the machine is used Steps must be taken to ensure that the marking and instructions for other equipment related to a safe use of this machine confor...

Page 17: ...re starting For explosive areas guards with a non sparking material are to be used Wet end If there is a possibility of a dangerous return flow after the shutdown of the pump a nonreturn device shall be installed in the outlet piping The pump must be sufficiently filled with the pumped liquid before starting with the exception of liquid ring pumps LM S air separating pumps R and pumps equipped wit...

Page 18: ...or non corroding liquids or acid resistant steel for corroding liquids The pump easily passes the required mechanical tests described in EN 13463 1 There are no light metal or plastic parts that need consideration or other relevant restrictions as described in EN 13463 1 The pump s design is such that it will not leak even in the event of a foreseeable malfunction In normal operation the pump cont...

Page 19: ...design rotation speed for the pump is indicated on a label attached to the pump body EN 13463 5 c Accumulation of an explosive mixture of gases or air in the pump All air or gas mixtures are discharged from the pump when liquid enters The pump is so designed that gases or air cannot accumulate outside the pump There is no ignition source EN 13463 1 AC 15 EN 13463 5 c IOM The clutch cover makes con...

Page 20: ... no ignition source EN 13463 5 c 6 IOM Ingress of water or other impurities into the bearings which leads to insufficient lubrication bearing failure and the overheating of bearings The installation operation and maintenance manual contains instructions on the maintenance and condition monitoring of bearings Failure caused by the ingress of water is shown as increased vibration of the bearings whi...

Page 21: ...no ignition source EN 13463 5 c 5 3 A solid object blocks the gap between the impeller and the side plate or the casing cover which leads to the overheating of the pump s external surface Does not apply to categories 2 and 3 There is no ignition source EN 13463 1 AC 15 IOM The pump runs against a closed valve for a long time which leads to pump breakage and overheating The installation operation a...

Page 22: ...e no differences in potential There is no ignition source EN 13463 1 AC 7 4 EN 13463 1 AC 11 EN 13463 5 c Accumulation of an explosive mixture of gases or air in the pump All air or gas mixtures are discharged from the pump when liquid enters The pump is so designed that gases or air cannot accumulate outside the pump There is no ignition source EN 13463 1 AC 15 EN 13463 5 c IOM The clutch cover m...

Page 23: ...nual 6 Safety signs affixed to the product The following warnings and informative signs concerning the essential safety aspects are permanently fixed on the product Safety signs must always be observed and kept clean and legible in any operating condition The user must always check that the symbols or items presented in those are understood by all user groups before putting the product into servic...

Page 24: ...ing situations affecting product safety The following inadequate operating situations always have consequences which have an immediate effect on the product safety and therefore they are not allowed in any operating conditions with this product Table 1 Typical inadmissible operating situations Cause Consequence Discharge valve not opened Inlet pressure or piping system resistance incorrectly estim...

Page 25: ...ion does not exceed the vibration severity limits given in Table 2 when measured at the manufacturer s test facilities These values are measured radially at the bearing housing at rated speed and flow when operating without cavitation A pump equipped with a specially designed impeller may exceed the limits given in Table 2 Table 2 Max r m s values of vibration velocity Pump installation Shaft cent...

Page 26: ...750 850 1100 1600 40 1000 1250 1100 1950 900 1050 1300 1900 50 1350 1650 1500 2600 1000 1150 1400 2050 65 1700 2100 1850 3300 1100 1200 1500 2200 80 2050 2500 2250 3950 1150 1300 1600 2350 100 2700 3350 3000 5250 1250 1450 1750 2600 125 3200 3950 3550 6200 1500 1900 2100 3050 150 4050 5000 4500 7850 1750 2050 2500 3650 200 5400 6700 6000 10450 2300 2650 3250 4800 250 6750 8350 7450 13050 3150 3650...

Page 27: ...t shall be limited to 1 4 times the maximum allowed value the actual forces and moments acting on each flange are governed by the following formula 2 M M F F 2 allow max actual 2 allow max actual Under the maximum allowance forces and moments the lateral displacement of the shaft end relative to the fixed point in space should not exceed the values indicated in Table 4 Table 4 Lateral displacement...

Page 28: ...A 79 75 70 70 70 70 70 22 80 A 81 77 70 70 70 70 70 23 40 A 75 70 70 70 70 70 23 50 A 77 70 70 70 70 70 31 100 A 83 79 70 70 70 70 70 31 125 A 81 73 70 70 70 70 31 150 A 75 70 70 70 70 32 65 A 72 70 70 70 70 32 80 A 72 70 70 70 70 32 100 A 74 70 70 70 70 32 125 A 76 72 70 70 70 33 80 A 74 72 70 70 70 70 33 100 A 76 74 70 70 70 70 33 125 A 79 76 72 70 70 70 41 200 A 81 78 74 71 70 41 300 A 80 77 73...

Page 29: ...4 81 80 79 77 77 71 400 A 88 86 84 83 82 79 79 71 500 A 90 89 85 85 84 81 81 71 600 A 91 89 86 86 85 84 81 72 300 A 88 84 84 82 81 79 79 72 400 A 89 85 85 85 81 81 79 72 500 A 87 86 85 84 83 81 72 600 A 89 88 86 85 85 84 Table 6 Sound power level LwA open impellers dB Pump size Pump types Pump rot speed rpm 3550 2950 1760 1480 1180 980 880 740 710 590 510 495 445 43 250 A 96 93 43 350 A 94 43 500 ...

Page 30: ... 50 APP WPP 76 73 70 70 70 70 70 22 50 NPP 76 70 70 70 70 70 22 65 APP 79 75 70 70 70 70 70 22 80 8S APP 81 78 70 70 70 70 70 22 80 NPP 70 70 70 70 70 23 50 APP WPP 77 70 70 70 70 70 31 65 EPP 81 78 70 70 70 31 100 10S APP 83 80 71 70 70 70 70 31 100 EPP 84 81 72 70 70 70 70 31 100 NPP 71 70 70 70 70 31 125 10P APP 82 72 70 70 70 70 31 150 APP 75 72 70 70 70 32 65 APP 79 71 70 70 70 70 32 80 8S AP...

Page 31: ...PP 85 82 78 75 73 70 70 53 150 APP WPP 87 84 80 77 75 72 71 53 200 APP EPP WPP 89 86 82 79 77 74 73 53 250 APP WPP 88 84 81 79 76 75 53 250 EPP 88 85 81 78 75 73 72 53 250 NPP 81 83 77 78 53 300 APP 89 85 82 80 77 76 53 300 EPP 90 87 83 80 78 75 74 54 300 EPP 84 84 79 79 54 400 APP WPP 87 87 82 82 78 78 54 500 APP 91 88 86 83 83 79 54 500 EPP 86 85 82 80 78 76 55 100 APP 90 87 83 80 78 75 55 200 A...

Page 32: ...70 31 100 EPP 72 70 70 70 70 31 125 10P APP 81 73 70 70 70 70 31 150 APP 75 70 70 70 70 32 65 APP 72 70 70 70 70 32 80 8S APP WPP 72 70 70 70 70 32 100 10S APP WPP 74 70 70 70 70 32 100 EPP 77 74 70 70 32 125 10P APP WPP 76 72 70 70 70 33 100 10S APP WPP 76 74 70 70 70 70 33 125 10P APP 79 76 72 70 70 70 41 150 EPP 77 74 70 70 70 41 200 APP 79 76 72 70 70 41 200 EPP 80 77 72 70 70 41 300 APP 82 79...

Page 33: ...Pump size Pump types Pump rot speed rpm 3550 2950 1760 1480 1180 980 880 740 710 590 51 300 APP 96 94 53 200 APP WPP 94 95 53 250 APP WPP 95 96 53 300 APP 97 97 54 400 APP WPP 98 95 54 500 APP 95 94 55 100 APP 98 95 55 300 APP EPP WPP 94 94 61 500 APP EPP 96 101 96 61 600 APP WPP 100 99 95 62 400 APP 99 99 94 Vortex impellers Table 11 Sound pressure level LpA vortex impellers dB Pump size Pump typ...

Page 34: ...d particles Ø mm A Process Pump Pump size Pump types Impeller type Open1 Open2 Special open1 Special open2 Low flow1 Vortex1 10 32 A 10 3 10 50 A 14 10 65 A 11 11 32 A 12 5 11 40 A 16 19 11 50 A 21 22 20 65 A 16 20 80 A 17 34 21 65 A 17 24 21 80 A 19 36 26 21 100 A 29 36 37 22 32 A 12 4 22 40 A 15 18 22 50 A 18 22 22 65 A 23 26 22 80 A 20 37 29 23 40 A 16 5 18 23 50 A 21 24 31 100 A 25 43 30 31 12...

Page 35: ...9 55 300 A 56 65 60 500 A 68 79 60 600 A 67 70 74 77 63 400 A 60 72 63 500 A 66 75 63 600 A 82 94 63 700 A 81 84 90 93 71 250 A 68 71 300 A 75 71 400 A 81 71 500 A 69 71 600 A 107 72 300 A 75 72 400 A 85 72 500 A 93 72 600 A 79 Table 13 Max size of solid particles Ø mm APP EPP NPP WPP Pump size Pump types Impeller type Closed1 Closed2 Open1 Open2 Special open1 Special open2 Vortex1 Low pulse1 11 3...

Page 36: ... 32 100 EPP 18 18 32 100 NPP 55 60 32 100 WPP 18 32 35 32 125 10P APP 26 32 32 32 125 WPP 26 42 40 33 80 NPP 45 50 33 100 10S APP 13 18 29 6 33 100 NPP 55 60 33 100 WPP 16 30 34 33 125 10P APP 22 29 29 11 41 150 EPP 36 35 41 200 APP 43 47 54 41 200 EPP 47 42 41 300 APP 46 56 70 42 150 APP 34 38 38 42 150 EPP 30 28 42 150 NPP 75 80 42 200 APP 35 48 49 42 200 EPP 39 39 42 200 NPP 85 85 42 250 EPP 54...

Page 37: ... 9 4 Tightening instruction for the flanges of AHLSTAR pumps 1 The purpose of the tightening torque is to provide an adequate pre tightening for the flange connection via screw forces The friction forces influencing in the screw thread and head have a great importance here This is why it is always necessary to lubricate both the threaded surface of the screw and the washer of the screw before inst...

Page 38: ...f the connection as the temperature changes and is therefore prohibited 5 The screws must be tightened using a torque wrench which is calibrated every two years in accordance with ISO 6789 6 The tightening must be performed in four stages Follow the order given in Fig 2 and first tighten 30 of the final torque After this follow the same order and tighten 60 of the final torque In the third stage t...

Page 39: ... steel case Table 15 Flange drillings of steel cases maximum torques DN Torque Nm EN 1092 1 PN10 EN 1092 1 PN16 EN 1092 1 PN25 8 8 12 9 8 8 12 9 8 8 12 9 32 90 90 90 90 90 90 40 120 120 120 120 120 120 50 180 180 180 180 180 180 65 150 150 150 150 150 150 80 170 170 170 170 170 170 100 220 220 220 220 220 220 125 270 270 270 270 350 350 150 410 410 410 410 410 410 200 450 450 300 300 280 280 250 5...

Page 40: ... 8 8 12 9 8 8 12 9 8 8 12 9 32 50 50 25 25 30 0 30 0 30 30 40 60 60 35 35 50 0 50 0 45 45 50 100 100 55 55 65 0 65 0 30 30 65 80 80 45 45 105 0 105 0 50 50 80 100 100 55 55 130 0 130 0 90 90 100 120 120 65 65 55 0 55 0 95 95 125 150 150 85 85 95 0 95 0 120 120 150 230 230 125 125 120 0 120 0 90 90 200 250 250 95 95 127 0 127 0 115 115 250 300 300 150 0 150 0 175 175 300 390 390 140 0 140 0 190 190...

Page 41: ...COPYRIGHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION SERIES 2 15 SPP id 120601 Replaces 110901 en N31569 2 AHLSTAR PROCESS PUMPS Hoisting and transfers 1 Safety measures 2 Hoisting and transfers ...

Page 42: ...be transferred by using skids etc on the ground level Lifting accessories must bear the identification of the manufacturer material and the maximum working load Lifting ropes used directly for lifting or supporting the pump or pump unit must not include any splicing other than at their ends Textile ropes and slings must not include any knots connections or splicing other than at the ends of the sl...

Page 43: ...ipment may differ from those presented N O T E If the ordered assembly contains an API baseplate follow the enclosed lifting instruction N31478 or a Heavy Duty baseplate follow the enclosed lifting instruction N31481 The crates or individual assemblies must never be dropped to the ground during transfer Refer to Figures 1 12 for examples of proper lifting techniques Fig 1 The transportation crate ...

Page 44: ... suction case of the pump and from under the motor Fig 3 With tangential pumps also ensure the balance of hoisting by means of a lifting eye fastened to the discharge flange Fig 2 Fig 3 Fig 4 The pump baseplate assembly is hoisted from under the suction flange of the pump and from the lifting eyes fastened to the baseplate Fig 5 With tangential pumps also ensure the balance of hoisting by means of...

Page 45: ...g eyes fastened to the suction and discharge flanges of the pump and to the end of the shaft Pay attention to the centre of gravity Fig 6 Fig 7 Wet end Fig 8 The radial volute case is hoisted from the lifting eyes fastened to the discharge flange Fig 9 The tangential volute case is hoisted from the lifting eyes fastened to the discharge flange It is recommended to place the lifting eyes symmetrica...

Page 46: ...ZER PUMPS FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Hoisting and transfers Spare parts and coupling Fig 10 Heavy 25 kg individual components can be lifted for example on a pallet Fig 10 Bearing parts Fig 11 The bearing is hoisted from the openings in the bearing housing and from the shaft Fig 11 ...

Page 47: ... is hoisted from the lifting eyes fastened to the mounting holes Fig 12 2 1 Motor gear and other accessories When hoisting the motor gear and other accessories the instructions provided by the relevant manufacturer must always be followed 2 2 Accessories If the assembly includes accessories such as a noise cover the cover may have to be removed before hoisting the assembly in order to prevent the ...

Page 48: ...COPYRIGHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION SERIES 2 15 SPP id 110901 en N31570 1 AHLSTAR PROCESS PUMPS Commissioning 1 Purchase inspection 2 Storage ...

Page 49: ...ould not be removed The pump bearings and drive elements must be properly protected against any foreign matter To prevent rusting or seizing lubricate the pump unit before storing and turn the pump shaft by hand at least once every two weeks 2 2 Long term N O T E The grease oil lubricants must be changed before the pump is taken into use W A R N I N G The rust preventives must be cleaned off caref...

Page 50: ...T SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Commissioning Observe the storage instructions of any accessory equipment e g electric motors included in the delivery If the pump unit is covered with a plastic sheet the bottom should remain open to allow for ventilation ...

Page 51: ...IGINAL INSTRUCTION SERIES 2 15 SPP id Version 14 131130 Replaces 130131 en N31571 4 AHLSTAR PROCESS PUMPS Installation at the site 1 Safety procedures before installation 2 Wet end 3 Sealing unit 4 Coupling unit 5 Baseplate 6 Drive motor ...

Page 52: ...ents of torque for fasteners presented in these instructions Note the special values for the titanium screws These shown values are only valid for fasteners where the moment values are not separately given Table 1 Fastener information Screw size Moments Nm Titanium screws 76 Moments Nm Rating Max value Rating Max value M5 3 5 4 0 2 1 2 7 M6 6 0 7 0 3 6 4 5 M8 14 18 8 9 11 M10 30 35 18 22 M12 50 60...

Page 53: ...below the pump the suction pipe must gradually rise towards the pump A sufficient length of the pipe end must be under the liquid level so that air cannot enter the pump Fig 2 Fig 2 Suction pipe above the pump The suction pipe must descend gradually towards the pump Fig 3 Fig 3 Extension piece The cones must be eccentric and in such a position that the upper level will be horizontal alternative A ...

Page 54: ...installed in the outlet piping C A U T I O N Never use the pump as a support for the piping system If the suction pipe has branches they must be located as far from the pump as possible and they must be formed advantageously with regard to the flow The suction pipe must always be made as short as possible Fig 5 A shut off valve must be placed in the discharge pipe after the potential check valve B...

Page 55: ...above the center line of the shaft seal Install the pipes as short as possible so that the shaft seal is at the lowest point Piping for degassing in a gas separator GM GS The piping for degassing is connected to the degassing outlet C50 21 of the pump The degassing outlet is on the right hand side when seen from the drive The precise size and direction of the connection are shown in the dimensiona...

Page 56: ...he pipe size generally suitable is shown in Table 3 Table 3 Suitable pipe sizes for degassing and return circulation Sealing unit size Outlet size C50 21 and C52 21 Suitable pipe size 11 DN25 DN25 or DN32 21 22 23 DN40 DN40 or DN50 31 32 33 DN40 DN40 or DN50 42 43 44 DN40 DN40 or DN50 51 52 53 54 55 DN50 DN50 or DN65 61 62 DN80 DN80 or DN100 Return circulation piping in an air separating pump R Th...

Page 57: ...iquid will run out of the degassing connection during pumping Lead and handle this liquid appropriately The mixture of gas and liquid discharging from the degassing connection is normally led back into the process by taking the degassing pipe underneath the liquid level see examples in Figures 8 9 and 10 The suitable pipe size for the degassing piping is determined on the basis of pipe length clog...

Page 58: ...S FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Installation at the site Starting with a straight suction pipe liquid level beneath the pump Fig 9 Degassing pipe Vacuum relief valve Pressure indicator Closed valve on startup Volume 0 Volume 2 Volume 0 and Volume 2 both as small as possible External water Minimum surface level ...

Page 59: ...or alignment procedures make sure the drive motor cannot be started by any means N O T E Satisfactory performance of the coupling depends on correct installation and alignment Degassing pipe Vacuum relief valve Pressure indicator Volume 0 Volume 2 Volume 1 Closed valve on startup Either external water or return circulation Back pressure valve Minimum surface level Volume 2 0 5 1 5 x Volume 1 Volum...

Page 60: ...0 C 212 F Carry out the hot alignment during production run immediately after the pump is stopped while the pump and the motor are still at the operating temperature The need for hot alignment depends on the extent of temperature differences and the coupling type chosen Check the alignment by measuring the angular and parallel misalignments in vertical 6 and 12 o clocks and horizontal 3 and 9 o cl...

Page 61: ...or the bottom beams are given in Table 4 In order to facilitate the alignment of the beams a so called concrete frame can be used The recommended accuracy for the installation of the beams is 10 mm in all directions The actual installation becomes much easier if the upper surfaces are horizontal Place foundation screws 918 61 in the fixing holes of the baseplate The distance between the foundation...

Page 62: ...ge ISO G COPYRIGHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Installation at the site Fig 13 Baseplate for pump and motor T base STD SLP Pump mounting sizes 11 12 13 21 22 23 24 25 26 31 32 33 34 35 41 42 43 44 45 46 47 48 49 4A 51 52 53 54 55 56 57 58 59 5A 5C 5D 5E 5F 5G 5H 61 62 ...

Page 63: ...holes is 10 mm Roughen the holes Clean the holes well by brushing and blasting Install the ampules into the holes Install the foundation screws 918 61 by hammering to the bottom of the holes and turn them a couple of rounds Let the glue of the ampules harden The screws can be loaded according to the following table Table 5 Chemical foundation screws Ambient temperature C Time of hardening Time for...

Page 64: ...m and the minimum dimension U2 according to Table 6 Each foundation screw is fixed to the baseplate by means of hexagonal nuts 2 pcs foundation screw Lift the pre installed pump and baseplate onto the mounting blocks so that the distance between the foundation and the lower edge of the baseplate is at least 50 mm and so that the foundation screws fit into their cavities and the pump is in its posi...

Page 65: ...ge ISO G COPYRIGHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Installation at the site Fig 15 Baseplate for pump and motor T base STD SLP Pump mounting sizes 11 12 13 21 22 23 24 25 26 31 32 33 34 35 41 42 43 44 45 46 47 48 49 4A 51 52 53 54 55 56 57 58 59 5A 5C 5D 5E 5F 5G 5H 61 62 ...

Page 66: ...and the loads of the foundation The amount of the concrete reinforcement depends on the size and the loads of the foundation and must be carefully calculated by the local civil engineer according to local standards and regulations Pour concrete into the mold The recommended strength grade for the concrete is about 35 MPa design strength K 35 The upper surface of the foundation is leveled so that i...

Page 67: ... INSTRUCTION USER S MANUAL AHLSTAR Installation at the site Fig 17 Baseplate for pump and motor T base STD SLP Pump mounting sizes 11 12 13 21 22 23 24 25 26 31 32 33 34 35 41 42 43 44 45 46 47 48 49 4A 51 52 53 54 55 56 57 58 59 5A 5C 5D 5E 5F 5G 5H 61 62 B2 min 110 when L1 2000 B2 min 140 when L1 2000 5 mm L1 min 110 when L1 2000 L1 min 140 when L1 2000 ...

Page 68: ...5L 63 64 65 66 67 68 74 75 77 78 79 7A 7B 7C 7D 5 3 Steel baseplate installed with mechanical feet Fasten each machine base 963 61 into the fixing holes in the baseplate and install the washers 554 66 under the hexagonal nuts There are 3 4 5 or 6 fixing holes Use the studs in the machine bases to adjust the baseplate to the correct height and horizontally and tighten the hexagonal nuts Fig 19 L1 m...

Page 69: ... coupling is even with the end of the shaft When installing the coupling also see instructions supplied by the coupling manufacturer Fasten the coupling spacer to the coupling half of the motor without the flexible element Check that the pump is aligned as accurately as possible to the middle of the fixing holes of the motor Lift the motor onto the riser blocks on the baseplate Align the coupling ...

Page 70: ...S 2 15 SPP id Version 14 120601 Replaces 110901 en N31572 2 AHLSTAR PROCESS PUMPS Operation 1 Safety procedures before start up 2 Starting the pump 3 Controls during the first run 4 Shut down procedure 5 Controls after the first run 6 Trouble shooting operation ...

Page 71: ...ding to the instructions W A R N I N G During operation leakage of hazardous substances can occur prepare proper means for a safe waste removal N O T E Pressure containing pump parts are not pressure vessels within the meaning of the regulations for pressure vessels C A U T I O N The pump will be damaged if run in the wrong direction 1 1 Wet end Leakage test The pump parts and the piping shall be ...

Page 72: ... FC FE QF BF G DS11 X X DS12 X X DS13 X X DS14 X X MS11 X X MS12 X X MS21 X X MS31 X MS32 X X MS35 X MS41 X X MS33 X X MS34 X X MS42 X X MS51 X X MS52 X X MS61 X MS71 X X X MS72 X X MS81 X X MS91 X PG11 X X X X Table 2 Sealing unit types liquid ring pump gas separator air separating pump Shaft seal fluid Sealing unit type N FR FE QF BF QFFR BFFR QFFE BFFE LM11 X LM11 X LM21 X LM21 X LM21 X LM21 X ...

Page 73: ...ion flushing fluid QFFE Quench sealing fluid External flushing fluid PT 0 05 MPa 3 l min For high vacuum level external flushing must be doubled or tripled BFFE Barrier sealing fluid External flushing fluid PT 0 05 MPa 3 l min For high vacuum level external flushing must be doubled or tripled Impellers with balancing holes pT p0 0 005 MPa Where pT pressure behind the impeller MPa p0 inlet pressure...

Page 74: ...unit is stored for a long time before installation and start up 1 4 Drive motor Direction of rotation D N Fig 1 Before commissioning always check the motor for correct rotation It is imperative to detach the coupling spacer before checking the rotation direction of the motor The motor rotation must be counter clockwise when viewed from the coupling end D end Fig 1 of the motor The pump rotation is...

Page 75: ...escribed in these instructions W A R N I N G If your pump has no gas separator GM GS liquid ring LM S or air separating R pump in the sealing unit make sure that the pump is sufficiently filled with the pumped liquid before starting C A U T I O N Observe immediately after start up the instrumentation showing the discharge pressure If the pressure is not quickly reached stop the motor and check cau...

Page 76: ...t least 30 80 drops a minute While tightening make sure that the stuffing box gland remains perpendicular to the shaft Follow the instructions given by the manufacturer of the sealing water equipment for filling bleeding and operation setup 2 2 Pumps equipped with liquid ring pumps LM S Open the sealing liquid and or flushing liquid valves and adjust the pressure and the flow rate to a suitable le...

Page 77: ...ired vacuum by means of the vacuum relief valve see pumps equipped with liquid ring pumps Start the motor Open the degassing valve between the pump and the potential degassing pump Open the discharge valve carefully until the desired liquid volume is reached If the pump is used as a self priming pump do not open the discharge valve until the degassing pump has sucked the pump full of liquid the pu...

Page 78: ...ssing pump Stop the motor Stop the motor of a potential degassing pump Close the suction valve if there is reason to doubt that the pumped liquid will flow out of the suction piping Close the cooling and flushing liquid valves if any If the pump has a sealing liquid valve it cannot be closed until the pump has been drained or until at least the pressure has been relieved from the pump During longe...

Page 79: ...tions Rotational speed too low Check the speed requirements limitations Flow resistance of the piping higher than the head generated by the pump Check resistancies and reduce losses Unexpected air gas content in the pumped liquid Consult manufacturer for further instructions Suction tank level low Check the required inlet suction head Table 4 Symptom Insufficient head Probable cause Remedy Unexpec...

Page 80: ...bration Probable cause Remedy Difference between inlet pressure and vapor pressure too small cavitation Check the suction piping arrangements Unexpected air gas content in the pumped liquid Consult manufacturer for further instructions Air leakage in suction opening suction piping or shaft seal Check the suction piping readjust the shaft seal Suction piping suction valve or impeller clogged Check ...

Page 81: ...ents The pump may operate below the recommended minimum flow cavitation Pump functioning below the recommended minimum flow cavitation Check the pumping system requirements Pump and motor incorrectly aligned Realign the assembly make sure there is no strain on the pump Bearings worn Reassemble the pump and replace the bearings if necessary Crooked or eccentric shaft Reassemble the pump straighten ...

Page 82: ...GHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION SPP id Version 14 141101 Replaces 140530 en N31573 5 SERIE 2 15 AHLSTAR PROCESS PUMPS Preventive maintenance 1 General 2 Wet end 3 Sealing unit 4 Bearing unit ...

Page 83: ...failures and aid in case of possible fault tracing analyses In the process industries one process downtime caused by a pump normally costs much more than the price of the pump Preventive maintenance consists of the following actions Bearing lubrication Temperature noise vibration monitoring and inspections Monitoring the discharge pressure capacity and power demand Inspections regarding corrosion ...

Page 84: ...gives a good view regarding the condition and wear of the hydraulic parts of the pump The follow up enables such preventive maintenance actions as clearance adjustments or parts renewals to be scheduled accordingly 1 4 Pump washdown The pump is designed to prevent external liquids from entering the bearing unit However direct spraying of high pressure water to the labyrinth rings 423 31 and 423 32...

Page 85: ...urns to obtain a 0 5 mm clearance between the sideplate and impeller After the adjustment tighten the hexagonal nuts whereby the adjusting screws will be locked The adjusting screw must not turn during tightening By turning the coupling by hand check that the pump can rotate freely The sideplate can be adjusted altogether 3 4 mm towards the impeller If further adjustment is needed change the impel...

Page 86: ...nd a wooden pattern having the same thickness as the shaft wearing sleeve part 524 21 in Table 2 and use a sharp knife to cut the packing rings straight and axially without overdimensioning or underdimensioning Fig 3 The dimensions of the stuffing box housing and the total length of the band to be cut without working allowances are given in Table 2 Fig 3 When packing new packing rings be very prec...

Page 87: ...50 6 100 x 132 x 16 1460 7 120 x 152 x 16 1710 1st ring 2nd ring lantern ring 3rd ring 4th ring stuffing box gland Gland packing Fig 4 3 2 Mechanical seal Mechanical seals are normally installed and adjusted at the factory before the delivery The general principle is that the mechanical seal does not leak at all The lifetime of a mechanical seal depends on the cleanliness and lubricating propertie...

Page 88: ...s worn more or otherwise damaged it must be replaced with a new one Dynamic seal plate type DS13 DS14 The expeller 604 21 design of the dynamic seal prevents the leakage of pumped liquid through the stuffing box during operation During shut down the leakage is prevented by the static seal design 435 21 Maintenance of shaft seals Dynamic seals do not normally require any preventive maintenance acti...

Page 89: ...perature shortens the lubrication interval to a half Table 5 Initial and re lubrication 60 Hz speeds of rotation Shaft size Initial lubrication g Re lubrication g Re lubrication interval 1 hours bearing housing temperature 55 C Impeller side Coupling side Impeller side Coupling side 445 rpm 510 rpm 590 rpm 710 rpm 890 rpm 1180 rpm 1780 rpm 3540 rpm 1 30 50 10 15 15000 10000 7000 3000 2 55 85 15 25...

Page 90: ...tructions 4 2 Oil lubrication C A U T I O N For delivery the bearing housing of the pump has been emptied of oil Remember to refill it before starting Bearing unit 1 6 Oil splash lubrication Oil bath lubrication For lubrication use only high quality mineral oils the viscosity of which is ISO VG 46 E g Shell Tellus Oil S46 Mobil DTE Oil Medium Viscosity of oil at the operating temperature must not ...

Page 91: ... the venting device 672 31 and add oil up to the middle of the sight glass 642 31 Fig 5 When pump is running oil level in the sight glass can be little variable With lower speed oil level can go little bit lower and higher speed go little up air is mixing into oil Screw the venting device 672 31 back in place See the oil volumes in Table 8 With using the constant level oiler Fig 6 Install the cons...

Page 92: ...g to Table 6 and more often if the operating conditions cause contamination or change in other properties of the oil used Table 6 Oil changes Surface temperature of bearing housing Oil change interval 65 C 1 year 75 C 6 months Table 7 Oil volumes Oil splash lubrication Shaft size Oil volume ml Bearing housing Constant level oiler Glass cup 1 140 140 100 2 350 140 100 3 460 140 100 4 1030 140 100 5...

Page 93: ...LZER PUMPS FINLAND OY ORIGINAL INSTRUCTION SERIES 2 15 SPP id Version 14 140901 Replaces 140530 en N32198 3 AHLSTAR PROCESS PUMPS Corrective maintenance 1 General 2 Pump unit 3 Wet end 4 Sealing unit 5 Bearing unit ...

Page 94: ...parts and assemblies are heavy unstable and due to design requirements they contain sharp edges e g impeller sideplate casing cover Use proper hoistings and supports to prevent personal injury W A R N I N G Hazardous substances must be kept away from the environment These substances should be collected and sent for proper handling All recyclable components should be taken to a proper recycling sys...

Page 95: ... pipes and sealing water equipment relating to degassing and shaft seal 6 Remove the guard jackets 686 51 and 686 52 and coupling 840 51 spacer 7 Drain oil from an oil lubricated bearing housing by unscrewing the threaded plug 903 32 Detachment of exchange unit 1 Unscrew the hexagon head screws 901 11 and the hexagon head screws 901 62 of the support foot from the baseplate 890 61 2 Suspend the ex...

Page 96: ...the gap by tightening 8 Fix the support foot 183 31 to the baseplate 890 61 with the hexagon head screws 901 62 9 Lubricate the bearing unit with oil or grease according to lubricating instructions in Section Operation 10 Install the coupling spacer according to the coupling manufacturer s instructions 11 Fix the coupling guard jackets 686 51and 686 52 The coupling guard must be adjusted so that t...

Page 97: ... 914 11 of the impeller 230 11 3 Prevent the shaft 210 31 from rotating at the coupling 840 51 end 4 Detach the impeller by turning it counter clockwise Push e g pieces of wood between the impeller vanes to ease the detachment Never use metal bars or the like because they might damage the impeller vanes Fig 2 Fig 2 3 2 Reassembly Installation of impeller W A R N I N G The socket head screw 914 11 ...

Page 98: ...hten the socket head screw to the torque value given in Table 2 Note the special values for the titanium screws Table 2 Impeller locking screw 914 11 Shaft size Screw size Torque Nm Titanium screws 76 Torque Nm Rating Max value Rating Max value 1 M10 30 40 18 22 2 M12 50 60 30 38 3 M16 130 140 70 92 4 M20 250 260 140 180 5 M24 420 440 250 310 6 M30 800 820 490 615 7 M36 1450 1500 850 1070 Secure t...

Page 99: ...he adjusting screws 909 11 and tighten the nuts 920 11 6 Fix the nuts 920 11 to the adjusting screws Fixed sideplate of pump type EPP open impeller 1 Screw the studs 902 11 tightly into place in the sideplate 2 Push the back up rings 516 11 and o rings 412 12 onto the studs against the sideplate 3 Install the sideplate into place in the volute case 102 11 4 Mount and tighten the nuts 920 11 Instal...

Page 100: ...he nuts 920 21 7 Unscrew the grub screws 904 21 and detach the thrust ring 475 21 from the shaft 8 Unscrew the hexagonal screws 901 33 of the adapter and draw the adapter out by using the same screws as extractors Mechanical seal standard integrated single types MS11 and MS12 1 Loosen the hexagon head screws 901 21 and remove the guards 683 21 and 683 22 2 Uncrew the hexagon head screws 901 21 3 B...

Page 101: ...e single on the shaft without shaft sleeve types MS31 MS32 and MS35 1 Loosen the hexagon head screws 901 21 and remove the guards 683 21 and 683 22 2 Unscrew the hexagon head screws 901 21 3 Unscrew the nuts 920 21 4 By using the said screws as extractors draw the case cover 161 21 out of the adapter 344 31 In heavier casing covers there is a threaded hole size M8 for lifting the cover by using an...

Page 102: ... the mechanical seal 433 21 will remain on the shaft 5 The mechanical seal can now be removed from the shaft and from the casing cover and dismantled according to the seal manufacturer s instructions 6 Remove the shaft wearing sleeve 524 21 from the shaft with an extractor 7 Unscrew the hexagon head screws 901 33 of the adapter and draw the adapter out by using the same screws as extractors Mechan...

Page 103: ...ad screws 901 21 and remove the guards 683 21 and 683 22 2 Unscrew the hexagon head screws 901 21 3 By using the said screws as extractors draw the case cover 161 21 out of the adapter 344 31 In heavier casing covers there is a threaded hole size M8 for lifting the cover by using an eye screw The components of the mechanical seal 433 21 come off the shaft 4 Unscrew the nuts 920 21 of the case cove...

Page 104: ...231 21 from the shaft Notice the compressor rings 487 21 between the suction impeller and mechanical seal 433 21 6 Remove the o rings 412 21 and 412 22 7 Remove the rotating part on the product side of the mechanical seal from the shaft 8 Pull the case 100 21 out of the guideway in the adapter 344 31 with the help of hexagon head screws 901 21 The static parts of the mechanical seal 433 21 will fo...

Page 105: ...e sliding surfaces 8 Unscrew the hexagon head screws 901 33 of the adapter and draw the adapter out by using the same screws as extractors Liquid ring pump ready fitted double type SM21 1 Detach the pipe 700 23 with the peripheral equipment from the case 100 21 if a vacuum relief valve 695 21 is included in the delivery 2 Unscrew the hexagon head screws 901 21 3 Detach the case cover 161 21 by lev...

Page 106: ...ew 901 22 of the stuffing box housing 451 21 Remove the seal ring 411 21 6 The static parts of the mechanical seal 433 21 can now be removed from the case cover 161 21 7 Unscrew the hexagon head screws 901 33 of the adapter and draw the adapter out by using the same screws as extractors Gas separator standard integrated double types GM21 and GM22 1 Unscrew the hexagon head screws 901 21 2 Detach t...

Page 107: ... place it into its proper groove in the thrust ring 475 21 Place the thrust ring 475 21 on the stuffing box housing 451 21 and fix it with the studs 902 21 and nuts 920 21 Do not tighten the nuts 4 Push the shaft wearing sleeve 524 21 onto the shaft against the shoulder 5 Push the stuffing box housing with its parts into its place in the adapter 344 31 6 Grease the o ring 412 22 slightly and place...

Page 108: ...ce in the adapter and fasten the hexagon head screws 901 21 Continue the assembly according to the following section Installation of impeller 8 When the exchange unit is fully assembled place the thrust ring 475 21 at the right position on the shaft and fasten the grub screws 904 21 The distance between the face of the cover plate for seal and the shoulder of the thrust ring must be 10 mm Fig 5 9 ...

Page 109: ...seal 433 21 with studs 902 21 washers 554 21 and nuts 901 21 5 Push the case cover 161 21 together with the incorporated parts onto the adapter 344 31 Fix the screws 901 21 6 Push the rotating part of the mechanical seal 433 21 onto the shaft against the shoulder Continue the assembly according to the following section Installation of impeller 7 Loosen the hexagon head screws 901 21 and mount the ...

Page 110: ...ions provided by the seal manufacturer Fix the screws 901 21 Tighten the nuts 920 21 5 Complete all the lockings fixings and other seal related jobs as described in the seal manufacturer s instructions Continue the assembly according to the following section Installation of impeller 6 Loosen the hexagon head screws 901 21 and mount the guards 683 21 and 683 22 Tighten the screws Mechanical seal el...

Page 111: ...o the shaft according to the seal manufacturer s instructions Tighten the nuts 920 21 4 Push the case cover 161 21 together with the incorporated parts onto the shaft Fix the screws 901 21 5 Push the rotating part of the mechanical seal onto the shaft against the shoulder Continue the assembly according to the following section Installation of impeller 6 Loosen the hexagon head screws 901 21 and m...

Page 112: ... suction impeller are tightly in their guideway pressed all the way to the bottom Measure the gap between the end of the suction impeller hub and the casing because the front face of the vanes is slightly conical Table 3 Gap between the suction impeller and casing Shaft size Gap mm 1 0 2 0 3 2 0 2 0 3 3 0 2 0 3 4 0 25 0 35 5 0 3 0 4 6 0 3 0 4 7 After adjusting the gap remove the parts again so as ...

Page 113: ...its hole in the case 100 21 16 Place the o ring 412 23 into its groove in the case 17 Install the case cover 161 21 into its guideway into the adapter 344 31 Tighten the hexagon head screws 901 21 Continue the assembly according to the following section Installation of impeller Liquid ring pump element single type SM11 1 Fix the adapter 344 31 into the bearing housing 330 31 with hexagonal screws ...

Page 114: ...r guideway pressed all the way to the bottom Measure the gap between the end of the suction impeller hub and the case because the front face of the vanes is slightly conical 7 After adjusting the gap remove the parts again so as to perform the actual assembly 8 Push the outer rotating part of the mechanical seal onto the shaft against the shoulder 9 Install the static part of the mechanical seal i...

Page 115: ...ller Gas separator standard integrated double types GM21 and GM22 1 Fix the adapter 344 31 to the bearing housing 330 31 with the hexagon head screws 901 33 2 Mount the rotating part on the atmospheric side of the mechanical seal 433 21 against the shaft sleeve 3 Push the static part of the mechanical seal 433 21 into the case cover 161 21 by means of the installation sleeve Follow the instruction...

Page 116: ...ollowing section Installation of impeller 9 When the exchange unit is fully assembled pull the thrust ring 475 21 and the static seal 435 21 against the shaft wearing sleeve 524 21 The assembly groove 3 mm x 0 5 mm at the thrust ring comes out 0 5 mm from stuffing box housing end Tighten the nuts 920 21 by hand so that the thrust ring is precisely aligned with the shaft Tighten the locking nuts Th...

Page 117: ... grooves in the bearing housing 330 31 6 Fasten the shaft with its bearings to a vice and detach the bearing nut 923 31 and lockwasher 931 31 7 Detach the antifriction bearings 320 31 and 320 32 and oil ring 644 31 not in the bath oil lubricated bearing from the shaft with an extractor or by means of a hammer and a punch 5 2 Reassembly N O T E It is absolutely necessary to place the bearings corre...

Page 118: ...he coupling side upwards 10 Grease the O rings 412 32 of the labyrinth rings 423 31 lightly and stretch them into their grooves Tap the labyrinth rings 423 31 with a soft mallet into the bearing housing 330 31 and bearing cover 360 31 Note that the drain holes in the labyrinth rings come underneath 11 Heat the bearing housing first slightly max 80 C to ease the installation of the shaft unit 12 Lo...

Page 119: ...ULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION USER S MANUAL AHLSTAR Corrective maintenance Shaft size mm Coupling side Impeller side Ød ØD Lmin Ød ØD Lmin 1 24 35 160 30 35 160 2 32 45 180 40 45 180 3 42 55 195 50 55 195 4 48 65 250 60 65 250 5 75 85 290 80 85 290 6 90 100 320 90 100 320 7 110 120 180 110 120 360 Fig 8 Ød ØD 2 L ...

Page 120: ...COPYRIGHT SULZER PUMPS FINLAND OY ORIGINAL INSTRUCTION SERIES 2 15 SPP id 110901 en N31575 1 AHLSTAR PROCESS PUMPS Spare parts recommendation 1 Recommended spare parts ...

Page 121: ... 11 Casing wear ring 1 2 2 2 3 3 4 50 412 O rings 2 4 6 8 8 9 10 100 Refer to the parts lists of the pumps when estimating the number of needed spare parts Table 2 Spare parts recommendation A Process pump Number of identical parts and units in various pumps 1 2 3 4 5 6 7 8 9 10 WEEN 1 Wet end Number of recommended spare parts Spare part kit 1 1 1 1 2 2 3 30 Service kit 2 4 6 8 8 9 12 150 102 11 V...

Page 122: ...eller 1 1 1 1 2 2 3 30 Refer to the parts lists of the pumps when estimating the number of needed spare parts 1 3 Bearing unit Table 4 Spare parts recommendation Number of identical parts and units in various pumps 1 2 3 4 5 6 7 8 9 10 BEUN 3 Bearing unit Number of recommended spare parts Spare part kit 1 1 1 2 2 3 4 50 Service kit 2 4 6 8 8 9 10 100 183 31 Support foot 1 10 210 31 Shaft 1 1 1 2 2...

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Sulzer AHLSTAR 2.15 Series, Installation,Operation And Maintenance Instruction

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