SPX FLOW Johnson Pump CombiProLine OH3 Instruction Manual Download

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CRL/EN (1810) 2.2

CombiProLine

Orginal instructions

Read and understand this manual prior to operating or servicing this product

INSTRUCTION MANUAL

Vertical heavy duty process in-line pump according to API 610 (OH3 & OH5)

Summary of Contents for Johnson Pump CombiProLine OH3

Page 1: ...1810 2 2 CombiProLine Orginal instructions Read and understand this manual prior to operating or servicing this product INSTRUCTION MANUAL Vertical heavy duty process in line pump according to API 610 OH3 OH5 ...

Page 2: ......

Page 3: ...on refers may only be put into operation after they have been installed in the way prescribed by the manufacturer and as the case may be after the complete system of which these pumps form part has been made to fulfil the requirements of Directive 2006 42 EC as altered most recently Declaration of incorporation Directive 2006 42 EC appendix II B Manufacturer SPX Flow Technology Assen B V Dr A F Ph...

Page 4: ...2 EC EN 1712 6 0 ...

Page 5: ...ought to the notice of third parties without our prior written consent SPXFLOW is a global multi industry manufacturing leader The company s highly specialized engineered products and innovative technologies are helping to meet rising global demand for electricity and processed foods and beverages particularly in emerging markets SPX Flow Technology Assen B V P O Box 9 9400 AA Assen The Netherland...

Page 6: ...4 INT EN 1512 1 2 ...

Page 7: ... 13 2 3 Type code 14 2 4 Serial number 15 2 5 Construction 15 2 6 Pump casing 15 2 7 Impeller 16 2 8 Pump cover 16 2 9 Wear rings 16 2 10 Mechanical seal 16 2 11 Bearing OH3 pump 16 2 12 Coupling OH3 pump 16 2 13 Application area 16 2 14 Re use 17 2 15 Scrapping 17 3 Installation 19 3 1 Safety 19 3 2 Preservation 19 3 3 Environment 19 3 4 Mounting OH3 pump 20 3 4 1 Installation of a pump unit 20 3...

Page 8: ...sembly Top Pull Out unit OH3 30 7 5 1 Disassembling the Top Pull Out unit OH3 30 7 5 2 Assembling the Top Pull Out unit OH3 30 7 6 Disassembly and assembly Top Pull Out unit OH5 31 7 6 1 Disassembly Top Pull Out unit OH5 31 7 6 2 Assembly Top Pull Out unit OH5 31 7 7 Replacing the impeller and the wear ring 32 7 7 1 Disassembling the impeller 32 7 7 2 Mounting the impeller 32 7 7 3 Disassembling t...

Page 9: ...10 1 1 Tightening moments for bolts and nuts 51 10 1 2 Tightening moments for cap nut 51 10 1 3 Tightening moments stud bolts for drain and seal flushing 51 10 1 4 Torques settings for nuts for pump casing 52 10 2 Permissible forces and moments on the flanges 53 10 2 1 Allowable forces and moments on suction and discharge flanges 54 10 2 2 Allowable forces and moments on the drain flange 54 10 3 G...

Page 10: ...8 CRL EN 1810 2 2 ...

Page 11: ...deliveries accordingly 1 2 Safety This manual contains instructions for working safely with the pump Operators and maintenance staff must be familiar with these instructions Installation operation and maintenance has to be done by qualified and well prepared personnel Below is a list of the symbols used for those instructions and their meaning Personal danger for the user Strict and prompt observa...

Page 12: ...rishly carelessly improperly and or negligently The products supplied become defective due to external circumstances beyond our control All parts which are liable to wear are excluded from guarantee Furthermore all deliveries are subject to our General conditions of delivery and payment which will be forwarded to you free of charge on request 1 4 Inspection of delivered items Check the consignment...

Page 13: ...o bear the total weight of the load Never go underneath a load that is being lifted If the electric motor is provided with a lifting eye this lifting eye is intended only for the purpose of carrying out service activities to the electric motor The lifting eye is designed to bear the weight of the electric motor only It is NOT permitted to lift a complete pump unit at the lifting eye of an electric...

Page 14: ...instructions for ordering them A fax order form is included in this manual You should always state all data stamped on the type plate when ordering parts and in any other correspondence regarding the pump This data is also printed on the label on the front of this manual If you have any questions or require further information with regard to specific subjects then do not hesitate to contact SPXFLO...

Page 15: ...hese requirements This has been demonstrated through extensive research and can be supported on the basis of advanced methods of calculation 2 2 Applications In general this pump can be used for thin clean or slightly polluted liquids These liquids should not affect the pump materials The maximum allowed system pressure and temperature and the maximum speed depend on the pump type and the pump con...

Page 16: ...haft sealing code according to API 682 Arrangement 1 1CW FX Contacting single wet seal with a fixed throttle bushing 1CW FL Contacting single wet seal with a floating throttle bushing Arrangement 2 2CW CW Liquid buffer fluid Dual contacting wet seals 2CW CS Gas buffer fluid or no buffer fluid Contacting wet inner seal with a containment seal 2NC CS Gas buffer fluid or no buffer fluid Non contactin...

Page 17: ... is one pump cover in various materials and for OH3 pumps one bearing bracket which is made from carbon steel The various designs of pumps are created by the addition of shaft seal cartridges These cartridges are standardized in the same three groups as the pump shafts and are designed in accordance with API 682 identical to ISO 21049 In addition to this various material varieties can be used for ...

Page 18: ...on consists of two angular contact bearings in O arrangement combined with a cylindrical roller bearing The bearings are grease lubricated The bearings on the coupling side with which the axial force is taken up are retained on the shaft by a shaft nut The outer ring of these bearings is retained by the bearing cover The cylindrical roller bearing on the impeller side takes up radial forces and is...

Page 19: ...s not always known the following instructions should be observed 1 Flush the pump properly 2 Make sure the flushing liquid is discharged safely environment Take adequate precautions and use the appropriate personal protection means like rubber gloves and spectacles 2 15 Scrapping If it has been decided to scrap a pump the same flushing procedure as described for Re use should be followed ...

Page 20: ...18 General CRL EN 1810 2 2 ...

Page 21: ...with the hot pump parts If there is danger of static electricity the entire pump unit must be earthed If the pumped liquid is harmful to men or the environment take appropriate measures to drain the pump safely Possible leakage liquid from the shaft seal should also be discharged safely 3 2 Preservation Before commissioning the pump remove any preserving agents and flush the pump thoroughly with h...

Page 22: ...led do the following 1 Remove the front guards 0270 Check if there is a key in both shaft ends 2 Clean the motor and pump shaft Grease both shaft ends with mounting grease 3 Fit both halves of the coupling to the pump shaft and the motor shaft respectively The front of the hub must be flush with the shaft end 4 Align the coupling in accordance with the following instructions 3 4 3 Alignment of the...

Page 23: ...for the alignment of the coupling halves are shown in Table 2 The values are maximums for each type of misalignment It is recommended that the coupling is initially aligned to 10 of these values to allow for inevitable movements during the life of the pump 3 5 Piping The piping to the suction and delivery connections must fit exactly and must not be subject to stress during operation For the maxim...

Page 24: ...t impurities from being drawn in When mounting place temporarily for the first 24 operating hours a fine gauze between suction flange and suction pipe to prevent internal pump parts from being damaged by foreign matter If the risk of damage continues to exist fit a permanent filter In case the pump is provided with a cooling chamber connect the cooling chamber to the supply and return lines of the...

Page 25: ...hen checking the sense of rotation 1 The sense of rotation of the pump is indicated by an arrow Check whether the sense of rotation of the motor corresponds with that of the pump 2 Let the motor run for only a short time and check the sense of rotation 3 If the sense of rotation is not correct alter the sense of rotation See the instructions in the user manual belonging to the electric motor 4 Fit...

Page 26: ...nce between suction and delivery side corresponds with the specifications of the pump s duty point 4 7 Noise The noise production of a pump depends to a great extent on the operating conditions The values stated in paragraph 10 5 Noise data are based on normal operation of the pump driven by an electric motor In case the pump is driven by a combustion engine or in case it is used outside the norma...

Page 27: ...quires re greasing after every 1000 hours of operation The bearings are filled with grease during assembly In case the pump is overhauled the bearing bracket and the bearings have to be cleaned and provided with new grease For recommended greases see paragraph 10 3 Grease 5 3 2 OH5 pump For maintenance of the motor bearings we refer to the instructions of the motor supplier concerned 5 4 Environme...

Page 28: ...he appropriate precautions first and protect yourself with the proper safety devices safety goggles gloves protective clothing To determine the source of the malfunctioning of the pump proceed as follows 1 Switch off the power supply to the pump unit Lock the working switch with a padlock or remove the fuse In case of a combustion engine switch off the engine and close the fuel supply to the engin...

Page 29: ...t choice of pump A number of the most frequently occurring failures as well as their possible causes are shown in the table below Table 3 Most frequently occurring failures Most common faults Possible causes see Table 4 Pump delivers no liquid 1 2 3 4 5 6 7 8 9 10 11 13 14 17 19 20 21 27 29 Pump has insufficient volume flow 1 2 3 4 5 6 7 8 9 10 11 13 14 15 17 19 20 21 28 29 Pump has insufficient h...

Page 30: ...Liquid viscosity differs from the calculated liquid viscosity 18 Pump operates when the liquid flow is too low 19 Wrong pump selection 20 Obstruction in impeller or pump casing 21 Obstruction in the piping 22 Wrong installation of the pump unit 23 Pump and motor not well aligned 24 Rotating part running out of true 25 Imbalance in rotating parts for instance impeller or coupling 26 Pump shaft is r...

Page 31: ...uch is the case it will be indicated in the text 7 3 Position numbers The position numbers used in the descriptions below refer to the figures shown in the description These numbers are also used in the general cross section drawings and the corresponding parts lists chapter 9 Parts 7 4 Liquid draining Make sure no liquid or oil gets into the environment Before starting any disassembly the pump sh...

Page 32: ...s 4 Remove the nuts 0810 and washers 0805 Tighten alternately both bolts 0820 until the pump cover 0110 is released 5 Pull the entire bearing bracket 2100 from the pump casing The entire bearing bracket of large pumps is very heavy Support it with a beam or hang it in a pulley sling 7 5 2 Assembling the Top Pull Out unit OH3 1 Fit a new gasket 0300 into the pump casing and fit the entire bearing b...

Page 33: ...ing by loosening the motor bolts 0950 This may result in irrepairable damage to the mechanical seal and the impeller 3 Remove the nuts 0810 and washers 0805 4 Pull the motor together with the entire lantern piece out of the pump casing The Top Pull Out unit large pumps is very heavy Support it with a beam or hang it in a pulley sling 7 6 2 Assembly Top Pull Out unit OH5 1 Mount a new gasket 0300 f...

Page 34: ...peller and the pump cover 0110 4 Remove the impeller key 1860 7 7 2 Mounting the impeller 1 Place the impeller key 1860 in the key way of the pump shaft 2 Push the impeller onto the pump shaft 3 Fit the cap nut For tightening moment of the nut see paragraph 10 1 2 Tightening moments for cap nut 4 Fit the set screw 1825 7 7 3 Disassembling the wear rings After removing the Top Pull Out unit see par...

Page 35: ...re 5 D 8 Clean the pump casing and impeller and carefully remove all bore dust and metal splinters 7 7 4 Assembling the wear rings 1 Clean and degrease the fitting edge of the pump casing and impeller where the wear ring is to be mounted 2 Fit the casing wear ring in the pump casing Take care it is not pushed out of alignment 3 Fit the impeller wear ring on the impeller Take care it is not pushed ...

Page 36: ... bolts 0850 and washer 0855 and knock the pump cover loose from the bearing bracket OH3 or lantern piece OH5 6 Pull the entire seal cartridge from the shaft 7 8 3 Mounting a cartridge seal 1 OH3 Put the bearing bracket in upright position impeller side up OH5 Place the electric motor with the shaft upright 2 Push the seal cartridge onto the shaft 3 OH3 Mount the pump cover 0110 in the correct posi...

Page 37: ...ring directly Use a mounting bush positioned against the inner raceway of the bearing and a normal hammer a soft hammer might loose some splinters which could damage the bearing Always apply a new locking washer 2570 when assembling bearings 7 9 2 Disassembling bearing 1 Dismantle the impeller and the shaft seal see paragraph 7 7 1 Disassembling the impeller and paragraph 7 8 2 Disassembling a car...

Page 38: ...of the cylindrical roller bearing Let the bearings cool down 3 Fit the locking washer 2570 and screw the lock nut 2560 on the pump shaft Tighten the lock nut and lock it by knocking a lip of the locking washer into the opening of the lock nut 4 Fit the inner circlip 2300 into the bearing bracket 2100 5 Fit the pump shaft with bearings starting from the motor side in the bearing bracket Knock at th...

Page 39: ...CRL EN 1810 2 2 Dimensions 37 CombiProLine 8 Dimensions For dimension see GAD enclosed with the delivery ...

Page 40: ...38 Dimensions CRL EN 1810 2 2 ...

Page 41: ...he item number and the description of the part 3 The pump number The pump number is stated on the label on the cover of this manual and on the type plate of the pump 4 In the event of different electric motor voltage you should state the correct voltage 9 1 2 Recommended spare parts Parts marked with a 1 2 3 are recommended spare parts 1 Start up spares 2 Initial spare parts one year operation 3 N...

Page 42: ... pump 0835 0800 0450 0400 0455 0805 0810 0830 0120 0100 0300 0110 0820 0250 0920 0930 0275 0940 0910 0210 0270 2430 2420 0920 0925 0930 0290 0890 0895 0896 0950 0960 0960 0955 1820 1825 0150 0155 0130 0135 0855 0850 2410 2415 2470 2475 2460 2465 0925 1220 1815 1810 1800 1900 1920 1905 1930 1950 ...

Page 43: ...ex 0155 3 set screw stainless steel duplex super duplex 0210 1 coupling 0250 1 lantern piece steel 0270 2 guard brass 0275 1 assembly plate brass 0290 4 adjusting cam stainless steel 03001 2 3 1 gasket stainless steel graphite duplex graphite super duplex graphite 0400 1 support steel 0450 3 bolt steel 0455 3 spring washer spring steel 0800 stud carbon steel 0805 washer steel 0810 nut carbon steel...

Page 44: ...asher steel 1920 1 flange carbon steel stainless steel duplex super duplex 1930 1 blind flange carbon steel stainless steel duplex super duplex 1950 1 gasket stainless steel graphite duplex graphite super duplex graphite 2410 1 arrow plate stainless steel 2415 2 rivet stainless steel 2420 1 motor 2430 2 lifting eye bolt steel 2460 1 name plate stainless steel 2465 4 rivet stainless steel 2470 1 na...

Page 45: ... 3 Bearing OH3 9 3 1 Sectional drawing bearing Figure 8 Sectional drawing bearing 1860 2210 2180 2200 2115 2125 2560 2570 2260 2320 2300 2310 2250 2120 2810 2110 2220 2177 2176 2175 2100 2172 2170 2171 0235 0276 0245 0240 2400 2405 2375 2815 ...

Page 46: ...21253 1 oil catcher bronze 2170 1 grease nipple stainless steel 2171 1 socket stainless steel 2172 1 pipe stainless steel 2175 1 grease nipple stainless steel 2176 1 socket stainless steel 2177 1 pipe stainless steel 2180 1 deflector rubber 22003 1 pump shaft 4140 steel stainless steel chrome steel stainless steel duplex super duplex 22103 1 coupling key steel 2220 1 deflector rubber 22502 3 1 cyl...

Page 47: ...drawing pump Figure 9 Sectional drawing pump 0450 0455 0400 0805 0810 0800 0820 0835 0830 0250 2430 1815 1810 1800 2420 1220 0950 0960 0100 0120 0300 0110 0240 0245 0235 0276 0130 0135 0155 0150 1825 1820 1860 1600 1605 1608 2460 2465 2410 2415 1900 1920 1905 1930 1950 ...

Page 48: ...ss steel duplex super duplex 0235 bolt stainless steel 0240 washer stainless steel 0245 washer stainless steel 0250 1 lantern piece steel 0276 2 guard stainless steel 03001 2 3 1 gasket stainless steel graphite duplex graphite super duplex graphite 0400 1 support steel 0450 3 bolt steel 0455 3 spring washer spring steel 0800 stud carbon steel 0805 washer steel 0810 nut carbon steel 0820 2 bolt sta...

Page 49: ...uper duplex 1930 1 blind flange carbon steel stainless steel duplex super duplex 1950 1 gasket stainless steel graphite duplex graphite super duplex graphite 2410 1 arrow plate stainless steel 2415 2 rivet stainless steel 2420 1 motor 2430 2 lifting eye bolt steel 2460 1 name plate stainless steel 2465 4 rivet stainless steel Item Quantity Description API 610 Material Classes S 1 S 6 S 8 C 6 A 8 D...

Page 50: ...uantity Description API 610 Material Classes S 1 S 6 S 8 C 6 A 8 D 1 D 2 1400 1 pipe nipple stainless steel duplex super duplex 1410 1 female connector stainless steel duplex super duplex 1420 1 pipe stainless steel duplex super duplex 1430 1 male connector stainless steel duplex super duplex 1504 1 orifice stainless steel duplex super duplex 1410 1420 1430 1504 1400 ...

Page 51: ...less steel duplex super duplex 2020 1 welding neck flange carbon steel stainless steel duplex super duplex 2025 1 orifice stainless steel duplex super duplex 2030 2 welding neck flange stainless steel duplex super duplex 2035 16 washer carbon steel 2040 4 stud bolt carbon steel 20501 2 3 3 gasket stainless steel duplex super duplex 2060 2 elbow stainless steel duplex super duplex 2070 1 pipe carbo...

Page 52: ...50 Parts CRL EN 1810 2 2 ...

Page 53: ...ening moments for cap nut 10 1 3 Tightening moments stud bolts for drain and seal flushing Table 5 Tightening moments for bolts and nuts Materials 8 8 A2 A4 Thread Tightening moment Nm M6 9 6 M8 20 14 M10 40 25 M12 69 43 M16 168 105 Table 6 Tightening moments for cap nut 1820 Size Tightening moment Nm M12 43 M16 105 M24 220 Table 7 Tightening moments stud bolts for drain 1900 and seal flushing 200...

Page 54: ...ze Lubricated Not lubricated Nm Nm 40A 125 1 M12 8x 69 80 40A 200 1 M12 12x 73 84 40AC 200 1 M12 12x 73 84 50A 200 1 M12 12x 73 84 50A 250 2 M12 12x 73 84 50B 200 1 M12 12x 73 84 50BA 200 1 M12 12x 73 84 80AA 250 2 M12 16x 73 84 100A 160 2 M12 12x 69 80 100AC 160 2 M12 12x 69 80 100AC 200 2 M12 12x 73 84 100A 250 2 M12 12x 73 84 100BC 250 3 M12 16x 73 84 ...

Page 55: ...orces and moments acting on the pump flanges due to pipe loads can cause misalignment of the pump and driver shafts deformation and overstressing of the pump casing or overstressing of the fixing bolts between the pump and the base plate Figure 12 Coordinate system Z Z Z Y Y Y X X X Z Y X Z Y X Z Y X ...

Page 56: ... 200 1330 1070 890 1930 950 470 720 1280 710 580 890 1280 460 230 350 620 50A 250 50B 200 1330 1070 890 1930 950 470 720 1280 710 580 890 1280 460 230 350 620 50BA 200 80AA 250 1780 1420 1160 2560 1330 680 1000 1800 1070 890 1330 1930 950 470 720 1280 100A 160 100AC 160 2490 3110 2050 4480 2300 1180 1760 3130 1420 1780 1160 2560 1330 680 1000 1800 100AC 200 100BC 250 2490 3110 2050 4480 2300 1180 ...

Page 57: ...0AC 200 50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 m h 3 Q 3 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400 4 H 6 7 8 10 15 20 25 30 40 50 60 70 80 100 5 150 50BA 200 100AC 200 50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 0 6 0 5 0 4 0 3 0 2 5 1 0 1 8 7 6 5 1 80 100 150 4 3 2 m m h 3 H 1 5 ...

Page 58: ... 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 H 8 10 15 20 25 30 40 50 60 70 80 100 m h 3 Q 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 500 150 m 200 50BA 200 100AC 200 50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 m h 3 Q H 5 6 7 8 10 15 20 25 30 40 2 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 4 3 4 3 2 m 50 ...

Page 59: ...50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 m h 3 Q 3 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 400 4 H 6 7 8 10 15 20 25 30 40 50 60 70 80 100 5 150 50BA 200 100AC 200 50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 0 6 0 5 0 4 0 3 0 2 5 1 0 1 8 7 6 5 1 80 100 150 4 3 2 m m h 3 H 1 5 6 7 8 10...

Page 60: ... 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 H 8 10 15 20 25 30 40 50 60 70 80 100 m h 3 Q 4 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 500 150 m 200 50BA 200 100AC 200 50A 200 100BC 250 80AA 250 100A 160 100AC 160 50B 200 50A 250 40A 200 40A 125 40AC 200 100A 250 m h 3 Q H 5 6 7 8 10 15 20 25 30 40 2 5 6 7 8 10 15 20 30 40 50 60 80 100 150 200 300 4 3 4 3 2 m 50 ...

Page 61: ...mp power kW at 1450 min 1 A sound power level B sound pressure level Figure 22 Noise level as function of pump power kW at 2900 min 1 A sound power level B sound pressure level 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 0 1 1 10 100 200 P kW dB A A 4103_A B 60 65 70 75 80 85 90 95 100 0 1 1 10 100 300 P kW dB A 4104_A A B ...

Page 62: ... of the motor 3 Determine the difference between both levels L1 L2 4 Find the differential value on the L1 L2 axis and go up to the curve 5 From the curve go left to the L dB axis and read out the value 6 Add this value to the highest value of both noise levels L1 or L2 Example 1 Pump 75 dB motor 78 dB 2 75 78 3 dB 3 dB on the X axis 1 75 dB on the Y axis 4 Highest noise level 1 75 dB 78 1 75 79 7...

Page 63: ... bearing 16 impeller 15 pump casing 15 shaft seal 16 Coupling 16 alignment 20 alignment tolerances 21 D Draining liquid 29 E Earthing 19 Electric motor connection 22 Environment 19 Environmental influences 25 F Faults 26 Foundation 19 G Grease 54 Guarantee 10 H Hoisting 11 I Impeller disassembly 32 mounting 32 Inspection motor 23 pump 23 L Lifting eye 11 Lubrication bearings maintenance 25 M Maint...

Page 64: ...fety 9 19 symbols 9 Scrapping 17 Serial number 15 Special tools 29 Start up 23 Static electricity 19 Storage 12 T Technicians 9 Tightening moments for bolts and nuts 51 for cap nut 51 for draining and seal flushing 51 for nut pump casing 52 Top Pull Out unit disassembly 30 Top Pull Out unit assembling 30 Transport 10 Type code 14 V Ventilation 19 W Wear ring assembly 33 disassembly 32 replacement ...

Page 65: ...der will only be dealt with if this order form has been correctly completed and signed FAX Nr ADDRESS Order date Your order number Pump type Execution Quantity Item No Part Article number pump Delivery address Invoicing address Ordered by Signature Telephone ...

Page 66: ...64 ORDFORM 1512 3 3 EN ...

Page 67: ... approvals certifications and local representatives please visit www spxflow com johnson pump SPXFLOW Corporation reserves the right to incorporate our latest design and material changes without notice or obligation Design features materials of construction and dimensional data as described in this bulletin are provided for your information only and should not be relied upon unless confirmed in wr...

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