Sundyne LMV-802 Installation, Operation & Maintenance Manual Download Page 10 | Manualshive

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Instruction and Operation Manual

SA-07-11-37 Rev Orig

6

Jan 2009

INSTALLATION

Inspection

Immediately inspect your Sundyne product upon
receipt of the equipment. Check for any
damage, which may have occurred during
shipment. Notify the carrier and Sundyne
immediately if damage is evident.

Note: The input shaft on the pump may not

turn freely due to seal drag and speed
increasing gear meshes. If the input
shaft does turn freely, and if rotation is
“not smooth,” damage may have
occurred during shipping.

Suction and Discharge Piping

Please adhere to the following best practices for
installing and maintaining suction and discharge
piping:

Install a suction strainer (12 mesh - .062" or

1.6mm opening) and clean the suction line
prior to starting the pump. This procedure
will protect the impeller from damage by mill
scale, welding slag, or other foreign particles
during initial startup.

Note: Sundyne Recommends installation of a

differential pressure instrument across
strainer to indicate strainer condition.

When installing piping to the pump, ensure that

all piping is supported independently from
the pump.

All piping must always line up with the pump

flanges.

Note: Never use force to position piping into

place at the flanged suction and
discharge connection locations. Failure

to do so may impose excessive strains
on the unit.

Avoid using elbow fittings near the suction

flange. When necessary, use long radius
elbow fittings. Sundyne recommends using
a straight pipe assembly of at least three
times the length of the pipe diameter
between an elbow and suction flange.

Note: Carefully select the size of pipe and

fittings to be installed so that friction
losses will remain low.

Never use a suction pipe that is smaller in

diameter than the pump suction inlet.

Sundyne recommends installation of a discharge

check valve to prevent reverse rotation.

Use block valves (both suction and discharge)

when isolating the pump during shutdown.
This practice will minimize process leakage
and prevent possible reverse rotation from
pump back-flow.

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Summary of Contents for LMV-802

Page 1: ...SA 07 11 37 Rev Orig Jan 2009 Installation Operation Maintenance Manual Sundyne Pumps Model LMV 802 SA 07 11 37 Rev Orig Jan 2009 ...

Page 2: ...he warranty period Sundyne s sole obligation shall be limited to alteration repair or replacement at Sundyne s expense F O B Factory of parts or equipment which upon return to Sundyne and upon Sundyne s examination prove to be defective Equipment and accessories not manufactured by Sundyne are warranted only to the extent of and by the original manufacturers warranty Sundyne shall not be liable fo...

Page 3: ...vicing the Gearbox 5 Auxiliary Lube Pump 5 Setting the Valves 5 Control Checklist 5 Process Conditions 5 Adjusting the Cooling Flow 5 Verifying Operating Conditions 5 INSTALLATION 6 Inspection 6 Suction and Discharge Piping 6 Seal Environmental Control System 7 START UP 8 Starting the LMV 802 8 Controlling the Pump During Startup8 Single Operation 8 Parallel Operation 8 NPSH Net Positive Suction H...

Page 4: ...Jan 2009 ii SPECIFICATIONS 29 Gearbox and Pump Torque Values 29 30 Pump Spare Parts List 31 Inducer and Stud 32 Pump Exploded View 35 Single Seal Arrangement 36 Double Seal Arrangement 37 Tandem Seal Arrangement 38 INDEX 39 ...

Page 5: ...WARNING Text accompanied by this symbol indicates that failure to follow directions could result in bodily harm or death ELECTRICAL HAZARD Text accompanied by this symbol indicates that failure to follow directions could result in electrical damage to equipment or electrical shock RECOMMENDED Text accompanied by this symbol indicates recommended usage REMINDER Text accompanied by this symbol indic...

Page 6: ...iece of protective equipment consider their compatibility For example safety glasses will not interfere with hearing protection equipment Be sure to clean all pieces of personal protective equipment immediately after each use Using Forklifts Any persons operating a forklift must have an active recognized operator license Note Before initializing forklift operation verify that the lift is in a safe...

Page 7: ...rming maintenance or repair Replace the guards immediately after working on the equipment and prior to start up EXPLOSION FIRE HAZARD Note Never use an acetylene torch open flame or heat to attempt to remove parts that have seized together in Sundyne equipment Any residual process gas or liquid that is flammable can result in an explosion or fire with potential for serious injury or death ...

Page 8: ...t the auxiliary piping conforms to Sundyne standards as indicated in the detailed specifications Verify all switch and instrument connections Verify that all switch and instrument settings are set to normal operating standards Calibrate all measurement equipment such as Flow meters ampere meters and pressure meters ect Installing a Seal Environmental Control System Install a system to control the ...

Page 9: ...rical circuit and move it to the hand position Check for oil leaks and recheck the oil level Setting the Valves To set the pump to the designated operating point start the pump with the suction valve in the open position while throttling the discharge valve Control Checklist Process Conditions Verify the following process conditions against the specifications in this manual Process conditions Suct...

Page 10: ...n of a differential pressure instrument across strainer to indicate strainer condition When installing piping to the pump ensure that all piping is supported independently from the pump All piping must always line up with the pump flanges Note Never use force to position piping into place at the flanged suction and discharge connection locations Failure to do so may impose excessive strains on the...

Page 11: ... pump seal environment as detailed on the specification sheet that accompanies each unit Note For most applications a standard control system can be obtained from the factory Ensure that the specified seal environmental control system is properly installed and that the ports are open or plugged as indicated in Figure 1 below Note Port 1 must always be open so that it is free to drain Figure 1 Seal...

Page 12: ... Controlling the Pump During Startup To ensure control of the pump during start up follow the start up procedures for your desired configuration Single Operation Start the pump with the suction valve open while throttling the discharge valve This will ensure that the pump will reach the design flow operating point If the process fluid is near its vapor press open the supply vessel seal cavity vent...

Page 13: ...ential that the pump be selected to mate properly with the system head curve to prevent the pump from operating on its curve where damage may be sustained from recirculation or cavitation It is also essential that once it is selected that it is properly controlled Use of flow control should be used in place of pressure control if variable flows are to be experienced Pressure control is a very diff...

Page 14: ...spended until the cause is determined and corrected Continued use may cause damage to the pump Resonance in the discharge line can accentuate noise vibration and damage to the pump primarily when a control valve is located an excessive distance downstream from the pump Entrained Gases The head and capacity of centrifugal pumps will be reduced by gas that is drawn in with the liquid Under normal op...

Page 15: ...exactly the same performance it is assumed that pump A produces a slight amount more head than pump B The pumps are arranged with a common manifold as shown in Parallel Units Common Valve figure Figure 3 Parallel Operation Figure 4 Parallel Units Common Valve The pressure in the manifold is set at P1 the flow through pump A indicated as A1 on the preceding curve At the same time the flow through p...

Page 16: ...necessary for repair Parenthetical numbers in the text correspond to item numbers in the parts list section Note The following replacement parts will be required as a result of pump disassembly and seal housing removal PART ITEM NO QTY Impeller Tab washer 5 1 O Ring Repair Kit 1 Thermal Barrier Gasket 87A 1 STEP 1 Remove nuts 914A from the pump casing studs STEP 2 Remove the driver and seal housin...

Page 17: ...g using a strap or chain wrench loosen the inducer or impeller nut Note Left hand thread STEP 3 continued Remove the inducer 9 STEP 4 Pry the impeller 2 from the drive shaft Note The impeller is dynamically balancedand should be replaced if it shows any sign of damage STEP 5 Remove the impeller key 4 ...

Page 18: ...ing to the driver These marks will ensure the seal housing will be in the correct position when reassembled STEP 7 Remove the seal rotating face 51A STEP 8 Remove seal housing 30 from the driver by removing hex head bolts STEP 9 Remove seal housing gasket 87A STEP 10 Remove lower mechanical seal mating ring ...

Page 19: ...1 Turn the seal housing over and remove the three hex head cap screws STEP 12 Remove the throttle bushing 21B and the throttle bushing O ring 936H STEP 13 Remove seal retainer spacer 19A STEP 14 Remove lower mechanical seal 60A and the front and back mechanical seal O rings ...

Page 20: ...all seal arrangements SINGLE SEAL Remove the throttle bushing 21B seal retaining spacer 19A mechanical seal 60A and seal spacer 52 DOUBLE SEAL Remove the upper mechanical seal 60B seal retaining spacer 19A seal rotating face 51C seal spacer 52 and lower mechanical seal 60A TANDEM SEAL Remove the upper mechanical seal 60B seal retaining spacer 19A seal rotating face 51B lower mechanical seal 60A se...

Page 21: ... action of the seal face washer Replace or rebuild faulty mechanical seals A seal may be rebuilt by replacing the following parts Seal face washer Wedge ring or O ring Retaining ring Springs Seal repair kits are available for most seals See specific information on seals contained in the data package that accompanied this pump Replace the seal rotating face if the wear track is rough or is worn to ...

Page 22: ...hanical seal and seal spacer STEP 5 Install the throttle bushing O ring onto the throttle bushing STEP 6 Install throttle bushing onto the seal retainer spacer STEP 7 Install the 3 throttle bushing hex head screws Note Torque to 100 In Lbs By installing these three screws all the parts installed to this point will be fastened to the seal housing ...

Page 23: ...ction and Operation Manual SA 07 11 37 Rev Orig 19 Jan 2009 STEP 8 Install the thermal barrier gasket onto the driver STEP 9 Install shaft sleeve onto the driver shaft STEP 10 Install the shaft sleeve O ring ...

Page 24: ...injury Use of a hoist also will help prevent damage to the thermal barrier gasket due to rough handling STEP 12 Install seal housing onto the driver using hex head bolts Note Torque to 40 Ft Lbs STEP 13 Install lower seal mating ring into the bottom of the seal housing STEP 14 Install the O ring and key into the impeller Sliding the O ring onto the impeller ...

Page 25: ... Jan 2009 STEP 14 continued Inserting the impeller key into the impeller STEP 15 Install the impeller onto the driver shaft STEP 16 Install inducer tab washer and inducer O ring onto the inducer Installing the inducer tab washer Installing the inducer O ring ...

Page 26: ...rig 22 Jan 2009 STEP 17 Install the inducer into the motor shaft Note Left hand thread STEP 18 Punch a tab into the inducer slot STEP 19 Prevent impeller from moving using a chain or strap wrench STEP 20 Tighten the inducer Note Torque to 36 40 Ft Lbs ...

Page 27: ... tabs on tab washer into impeller holes STEP 22 Flatten all the remaining tabs until flush with the impeller STEP 23 Install case O ring onto seal housing STEP 24 Lower the driver assembly onto the pump case Note Use hoist to prevent personal injury or possible damage to the pump ...

Page 28: ...Instruction and Operation Manual SA 07 11 37 Rev Orig 24 Jan 2009 STEP 25 Install case nuts to fasten driver assembly to the pump casing Note Torque to 250 Ft Lbs ...

Page 29: ...ion if pump has inducer Direction of driver shaft rotation must be as shown by arrow on pump casing Note Pump and driver rotate in the same direction Insufficient flow or head rise Flow too high Check head rise and flow rate against performance curve Adjust system conditions to design head flow specified on performance curve Wrong direction of driver shaft rotation It is possible for the pump to d...

Page 30: ...r or pump Remove driver and check for freedom of rotation of driver and pump Mechanical damage to diffuser throat Material buildup or corrosion of diffuser bowl area or seal housing surface behind impeller Disassemble and inspect Check diffuser bowl throat and seal housing area behind impeller for material buildup Clean these areas of all obstruction and restore surfaces to a smooth polished finis...

Page 31: ... drain port 2 or 7 to prevent ice formation on atmospheric side of seal during startup Use single seal with throttle bushing and purge of dry nitrogen gas Install double or tandem seal if ice is caused by water in process fluid or supply external seal flush of compatible fluid which does not contain water Worn or damaged seal Disassemble seal and rebuild or replace per instructions in maintenance ...

Page 32: ...d or broken May be caused by damage at assembly or thermal shock caused by 1 seal running dry or 2 rotating face spinning on shaft or 3 loss and recovery of buffer fluid continued Install double seal Ensure that buffer fluid is always present during operation Chemical attack of seal faces seal parts or o rings Investigate fluid properties and determine suitable materials for replacement ...

Page 33: ...n lbs 11 11 5 N m 905F Throttle Bushing Mechanical Seal 1 4 20 x 12 95 102 in lbs 11 11 5 N m 905G Double Seal with Spacer 1 4 20 x 3 4 95 102 in lbs 11 11 5 N m 914A Case Nuts 3 4 10 250 275 ft lbs 340 375 N m 914A Case Nuts 7 8 9 300 330 ft lbs 405 445 N m 905A Seal Housing to Gearbox 3 8 16 x 1 3 4 35 40 ft lbs 47 54 N m 905P Separator 1 4 20 x 5 8 95 102 in lbs 11 11 5 N m Pumps Compressors NA...

Page 34: ...QTY ITEM NO PART NAME QTY 1 2 3 4 5 30 87A 115A 905A Pump Casing Impeller Impeller Bolt Impeller Key Impeller Tab Washer Seal Housing Gasket Shaft Seal Driver Hex Head Cap Screw 1 1 1 1 1 1 1 1 4 911 914A 914B 916S 924B 924D 936A 936F 936G Stud Nut Nut Washer Bull Plug Bull Plug O Ring Packing O Ring Packing O Ring Packing 6 6 4 4 2 1 1 1 1 Recommended Spare Parts ...

Page 35: ...Instruction and Operation Manual SA 07 11 37 Rev Orig 31 Jan 2009 Inducer and Stud Figure 6 Inducer and Inducer Stud Figure 7 Discharge Orifice ...

Page 36: ...Figure 8 Centrifugal Separator Table 5 Centrifugal Separator Parts List ITEM NO PART NAME QTY 90 Separator Orifice 1 91 Separator Fitting 1 905P Hex Head Cap Screw 2 916L Washer 2 918L Pin Alignment 1 936U O Ring Packing 1 936Z O Ring Packing 1 Recommended Spare Parts ...

Page 37: ...e Mechanical Seal Lower Mechanical Seal Upper O Ring O Ring 1 1 1 4 2 1 1 1 1 1 8 4 1 1 2 2 2 8 4 TANDEM SEALS 50A 50B 51A 60A 60B 60B 51B 936H 936J Shaft Sleeve Lower Shaft Sleeve Upper Seal Rotating Face Mechanical Seal Lower Mechanical Seal Upper Mechanical Seal Upper Gas Seal Rotating Face O Ring O Ring 1 1 1 1 1 4 3 1 1 1 1 1 1 1 8 6 1 1 2 2 2 2 2 8 6 Note Seal repair kits for standard seals ...

Page 38: ...Instruction and Operation Manual SA 07 11 37 REV ORIG 34 JAN 2009 Pump Exploded View ...

Page 39: ... 61A 62A Seal retaining spacer Throttle Bushing Slinger Sleeve Seal Rotating Face Seal Spacer Mechanical Seal Retainer and Drive Sleeve Assembly Seal Face Washer 1 1 1 1 1 1 1 1 63A 64A 65A 68A 905F 916B 936H 936J Seal Spring Back Up Disc Seal Retaining Ring Seal Spring Seal Wedge Ring Hex Head Cap Screw Washer O Ring Packing O Ring Packing 1 1 6 1 3 3 4 1 Recommended Spare Parts Recommended Seal ...

Page 40: ...ng Face Seal Spacer Mechanical Seal Lower Retainer Drive Sleeve Assembly Seal Face Washer Seal Spring Back Up Disc Seal Retaining Ring Seal Spring _Seal Wedge Ring 1 1 1 1 1 1 1 1 1 1 6 1 60B 61B 62B 63B 64B 65B 68B 905F 916B 936H 936J Mechanical Seal Upper Retainer Drive Sleeve Assembly Seal Face Washer Seal Spring Back Up Disc Seal Retaining Ring Seal Spring Seal Wedge Ring Hex Head Cap Screw Wa...

Page 41: ...ve Sleeve Assembly Seal Face Washer Seal Spring Backup Disc Seal Retaining Ring Seal Spring Seal Wedge Ring Mechanical Seal Upper Retainer and Drive Sleeve Assembly Seal Face Washer 1 1 1 1 1 1 1 1 1 1 1 6 1 1 1 1 63B 64B 65B 68B 60B 61B 62B 65B 68B 69B 905F 916B 936H 936J Seal Spring Back Up Disc Seal Retaining Ring Seal Spring Seal Wedge Ring Mechanical Seal Upper Alternate Gas Seal Retainer Sea...

Page 42: ...n 9 Operation of Sundyne Pumps 10 Parallel Operation 8 11 Personal Protective Equipment 2 Piping Connections 4 Pre Commission Checklist 4 Pressurizing Fluid Loop 5 Preventative Machine Guards 3 Prevention 9 Process Conditions 5 Pump Exploded View 34 Pump Mechanical Seals 27 Pump Spare Parts List 30 Recirculation 9 Recommended Seal Spare Component Parts 36 Recommended Spare Parts 36 Seal Environmen...

Page 43: ...International S A 13 15 Blvd Eiffel B P 30 21604 Longvic Cedex France Phone 33 380 383300 Fax 33 380 383366 Sundyne HMD Kontro Sealless Pumps Brampton Road Hampden Park Industrial Estate Eastbourne East Sussex BN22 9AN Great Britain Phone 44 1323 452000 Fax 44 1323 503369 Sundyne Marelli Pumps Ctra Madrid Toledo KM 30 8 45200 Illescas Toledo Spain Phone 34 925 53 45 00 Fax 34 925 51 16 00 ...

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