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Installation and Operation Manual

SA-07-11-87, Rev A

January 2019

INDEX

Auxiliaries, 5

Chemical Use, 4

Common Parts List, 54

Control Checklist, 6

Controlling the Pump During Startup, 15

Cryogenic Applications, 11

Cryogenic Seal Installation, 47

Disassembling the LMV-803, 20, 23

Dismantling Precautions, 19

Driver Instructions, 5

Driver Rotation Check, 5

Electrical Installation, 12

Electrical Safety, 4

Entrained Gases, 16

Equipment and Safety, 3

Explosion/Fire Hazard

, 4

Fall Protection, 4

Inspection, 8

INSTALLATION, 8

Installation and Start-Up Checklist, 7

ISO 9001, 3

Lifting, 3

Liquid Buffer System, 11

Lubrication, 13

Machine Guarding, 4

MAINTENANCE, 19

Minimum Flow Conditions, 16

Moving the Unit, 20

Operating Conditions, 6

Operation of Sundyne Pumps, 16

Parallel Operation Control, 15, 17

Personal Protective Equipment, 3

Piping Connections, 5

Pre-Commission Checklist, 5

Pressurizing Fluid Loop, 6

Pump Diagnostics, 50

Pump Familiarization, 5

Pump Removal from Pipe Work, 19

Reassembling the LMV-803Lr, 33

Seal Environmental Control System, 10, 11

Setting the Valves, 6

Shaft and Lip Seal, 30

Shimming the Extended Motor Shaft and Bearing

Box Assembly, 44

Single Operation Control, 15

SPECIFICATIONS, 53

START UP, 14

Start Up Checklist, 6

Start-Up Procedures, 14

Storing Your Pump Long-Term, 8

Storing Your Pump Short-Term, 8

Suction and Discharge Piping, 9

Suction Conditions, 16

Sundyne Centrifugal Pumps, 1

System Head Curve, 17

Testing the Equipment, 4

Text Symbols, 2

TROUBLESHOOTING, 50

Using Forklifts, 3

Venting, 6

Содержание LMV-803Lr

Страница 1: ...http www sundyne com Installation Operation Maintenance Manual Sundyne Pumps Model LMV 803Lr ...

Страница 2: ...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 for damage or ...

Страница 3: ...Revisions December 2015 Original Release January 2019 Update Introduction Content Add Cryogenic Options Revised shimming process IOM Location Numbers updated ...

Страница 4: ... 6 Venting 6 Setting the Valves 6 Control Checklist 6 Verifying Operating Conditions 6 Installation and Start Up Checklist 7 INSTALLATION 8 Inspection 8 Storing Your Pump Short Term 8 Storing Your Pump Long Term 8 Suction and Discharge Piping 9 Net Positive Suction Head 10 Seal Environmental Control System 11 Cryogenic Applications 11 Liquid Buffer System 11 Electrical Installation Grounding 12 LU...

Страница 5: ... 31 Diffuser Removal 32 Assembling the LMV 803Lr 33 Diffuser Assembly 33 Assembly Extended Shaft Motor 34 Assembly Bearing Box Configuration 36 Assembly All Configurations 38 Shimming 44 Shimming 44 Spring Energized Seal Installation 47 Diffuser and Pump Case 47 Shaft 47 Inducer 48 TROUBLESHOOTING 50 Pump Diagnostics 50 SPECIFICATIONS 53 Parts List 54 Extended Shaft Motor Configuration 56 Bearing ...

Страница 6: ...sociated with conventional seals The compact and rugged API 682 cartridge seal is designed specifically for the Sundyne LMV 803 providing operators and maintenance engineers with an economical alternative to standard seal configurations in a convenient package that eliminates errors in installation This manual presents installation servicing troubleshooting maintenance and spare parts information ...

Страница 7: ...at failure to recognize these hazards could result in injury or even 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 indicates a reminder to perform an action EQUIPMENT...

Страница 8: ...te and the appropriate Health and Safety data sheets Wearing Personal Protective Equipment To ensure safety protective equipment must be worn at all times when installing performing maintenance or repairing equipment The following safety recommendations must be adhered to for optimum safety Safety glasses with side shields that meet ANSI Z87 1 standard for impact resistance must be worn at all tim...

Страница 9: ...re Using Chemicals Any chemicals to be used must be accompanied by a relevant safety data sheet SDS in accordance with government legislation If applicable use chemical proof gloves An eye wash station or equivalent should be available in the event of injury If any hazardous or flammable chemicals pass through the equipment a complete decontamination of the equipment is required Protection from Fa...

Страница 10: ... is included in the final data package Verifying Auxiliaries Before start up verify that the following auxiliaries are met Check the utility connections Verify that 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 ...

Страница 11: ...rt up This can be accomplished with a valve connected to either a flush or vent depending on seal type 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 Verifying Operating Conditions Verify the following parameters against the specifications on the Specification she...

Страница 12: ...ngs Do process conditions suction pressure suction temperature discharge header pressure and specific gravity agree with specification sheet information DO NOT test the pump on water unless it is designed for water Check with your representative or Sundyne if you must test on a different fluid than shown on the specification sheet Prior to starting the unit have you opened the suction valve fully ...

Страница 13: ... damage may have occurred during shipping Storing Your Pump Short Term If your Sundyne pump is not to be installed immediately but within the next 6 months protect it from exposure to moisture and dust The pump should be left undisturbed in its transportation packaging and stored in a dry area and not subjected to vibration If removal from the packaging is necessary the pump should be stored cover...

Страница 14: ...y mill scale welding slag or other foreign particles during initial startup After about three months a permanent mesh strainer is installed Note Sundyne recommends installation of a differential pressure instrument across strainer to indicate strainer condition 2 When installing piping to the pump ensure that all piping is supported independently from the pump 3 All piping must always line up with...

Страница 15: ... will wear rapidly Cavitation starts when the pressure at the pump suction falls near to the value of the vapor pressure of the pump liquid and this varies with temperature At the time the pump is selected the NPSH available will have been calculated as per the following method NSPH available Ps Vp Hs Vs Hf Where Ps Absolute pressure in suction vessel Vp Vapour pressure of liquid Hs Total static h...

Страница 16: ...t nomenclature may vary from API designations and seal manufacturers Refer to the unit seal drawing for connection designation Cryogenic Applications The 803Lr when configured for cold services can operate with process temperatures to 200 F 123 C These applications require the use of a bearing box and heat trace around the cartridge seal Heat trace is necessary to prevent ice buildup on the seal a...

Страница 17: ... electrical connection will not overload the power supply Provision shall be made to enable electrical isolation of the equipment Figure 5 Grounding Location If the unit is not attached to a sole plate or base grounding is recommended from the base of the pump case through the provided 5 8 11 UNC threaded hole and wired to ground with a suitable grounding cable by electrically skilled persons or s...

Страница 18: ... 11 87 Rev A 13 January 2019 LUBRICATION Lubrication Specification With OH5 configurations refer to the driver s instruction for lubrication requirements In units outfitted with a bearing box OH3 refer to the Bearing Box IOM for information ...

Страница 19: ...connections and set points calibrate flow instruments and other transmitters 4 Flushing screens should be installed in all field assembled piping connections 5 Check the pump specification sheet and outline drawings for seal environment requirements Be sure that the seal housing port piping is properly connected If double seals are used buffer fluid must be pressurized before suction pressure is a...

Страница 20: ...charge piping of each pump Note Sundyne recommends installing separate bypass loops around each pump for additional operational flexibility 1 Start the first unit as described in the Single Operation instructions 2 Start the second unit with the bypass orifice valve set to maintain the flow above minimum flow 3 Open the discharge valve on the second unit so that the design flow of both units is ma...

Страница 21: ...can be prevented by maintaining suction pressure at a high enough level and suction temperatures low enough to maintain Net Positive Suction Head NPSHa available greater than Net Positive Suction Head NPSHr required by the pumps Minimum Flow Conditions Vibration and noise will occur during operation of centrifugal pumps if either of two conditions exist Internal flow separations Recirculation at l...

Страница 22: ...as a significant angle of intersection with system curves D and E The system curve D could represent a system with the control valve wide open while curve E could represent the same system but with the throttle valve closed to reduce flow from flow 1 to flow 2 Pump curve B on the other hand will provide only flow 2 even with the control valve wide open curve D When the control valve is partially c...

Страница 23: ...the same performance curves At the design point Q1 with the valve open both pumps are operating at the same flow and head However as the system curve changes with the valve positioning Q2 pump A can produce a higher head than pump B In this case pump B will stop flowing altogether causing it to operate in an unstable minimum flow condition Since pump B would effectively be deadheaded the fluid in ...

Страница 24: ...lly before dismantling Ensure that the electrical switch gear cannot be operated while any work is being carried out on the pump Close suction and discharge valves Block valves and lockout Always drain the pump casing of product before removing the pump from its associated pipework Flush out the pump casing and shroud with a compatible flushing liquid and drain away to a safe area Check with your ...

Страница 25: ...ust go on the correct side Correct locations will have the brackets parallel to the pump case flange faces Bolt the lifting brackets to the seal housing using the 6 seal housing nuts finger tight DO NOT TORQUE THE LIFTING BRACKET NUTS YET Note Lifting Brackets are included with the OH5 Direct Drive units Brackets are not required with OH3 Bearing Box configurations NOTE Motor Bearing Box Cartridge...

Страница 26: ... lifting hanger using the motor s integrated lifting feature holes this may require removal of the motor s lifting ears Note that these bolts will NOT take any vertical load and are merely intended for anti rotation of the motor assembly 1 04 Secure the Lifting Hanger shackle to an overhead lifting devise and carefully lift pump assembly and move as needed ...

Страница 27: ...ard covers 8 screws from the 4 coupling guard covers Remove the center section of the coupling 1 02 Remove 4 nuts from the bolts connecting the coupling housing to the bearing box Lift motor and coupling housing off the pump assembly 1 03 Install 2 5 8 eye bolts to bearing box housing Lift pump assembly and move as needed ...

Страница 28: ...ent components are of similar size Work should be carried out in a clean area where possible For maintenance purposes the pump casing may be left in the pipework whilst the main part of the pump is back pulled OR the complete pump can be removed from the pipework Maintenance work should be carried out in a workshop or suitable work area It is recommended to remove and discard all O rings during di...

Страница 29: ... BRACKET BOLTS YET Note Motor Cartridge Seal Housing Cartridge Seal Removed for clarity 1 02 Install the Lifting Hanger using 2 bolts nuts per side Tighten each size With the Lifting Hanger securely bolted to the Lifting Brackets tighten the Lifting Bracket bolts into the seal housing NOTE Motor Cartridge Seal Housing Cartridge Seal removed for clarity 1 03 Not applicable to the Bearing Box config...

Страница 30: ...fting devise to prevent motor assembly from tipping Remove remaining 8 seal housing nuts 1 05 Lift top assembly off of pump case using the Lifting Hanger shackle and an overhead lifting devise The top assembly consists of the motor cartridge seal cartridge seal housing seal housing diffuser cover impeller and inducer ...

Страница 31: ...the overhead lifting device attached to the Lifting Hanger shackle for stability 1 07 Remove the inducer and inducer stud then pull off the impeller and o ring Note that the inducer stud is left hand thread turn inducer clockwise to loosen NOTE In cryogenic applications the grooves for the seals are highly polished and care must be taken to avoid any scratches or nicks Note Left hand thread Note R...

Страница 32: ... held by a 2nd person helping with the disassembly Using a socket or wrench continue tightening the jacking screw until the impeller breaks free and slips off of the shaft Note The impeller is dynamically balanced and should be replaced if signs of damage or excessive wear are detected 1 09 Lift the top assembly off of the crates and set on top of blocks placed under the diffuser cover as shown be...

Страница 33: ...w holes However it is not recommended to use the diffuser cover screws as jacking screws due to the possibility of damage to the screw ends 1 11 With the top assembly resting securely back on the crates from STEP 8 install Seal Spacers between the rotating collar and the seal gland before loosening the collar lock screws The spacers may be provided with ship loose components or attached to the sea...

Страница 34: ...essary to slightly rotate the shaft to position the screws for access around other bolts Loosen difficult to access screws first before attempting to loosen the remaining Note Do NOT remove the seal spacers while loosening or gaining access to collar screws Spacers may be repositioned but not removed For disassembly with an extended shaft motor see Disassembly Extended Shaft Motor For disassembly ...

Страница 35: ...t o ring is being replaced gently pry the o ring over the splines of the shaft and remove it Note In cryogenic applications with spring energized seals the seal may need to be cut in order to be removed Exercise caution to not scratch the gland surface in the process 1 15 Remove the 4 bolts anchoring the cartridge seal to the seal housing and remove the cartridge seal The motor coupling housing ca...

Страница 36: ...LETED 1 13 Remove the 4 bolts anchoring the bearing box to the seal housing Carefully lift the bearing box off of the seal housing using eye bolts or similar lifting devise 1 14 Remove the 4 bolts anchoring the cartridge seal to the seal housing When removing the cartridge seal make sure to keep the o ring under the seal together with the cartridge seal for re use ...

Страница 37: ...olts Once removed if the o rings need to be replaced remove from their respective grooves on the bottom of the diffuser Three o rings total NOTE On cryogenic applications no seal exists on the diffuser eye NOTE In cryogenic applications the grooves for the seals are highly polished and care must be taken to avoid any scratches or nicks Diffuser Eye O Ring ...

Страница 38: ...the pump case On cryogenic applications no seal is used on the diffuser eye diameter NOTE On cryogenic applications no seal exists on the diffuser eye NOTE In cryogenic applications the grooves for the seals are highly polished and care must be taken to avoid any scratches or nicks 1 02 Align the witness marks on the pump case and diffuser Press diffuser into place so the top is flush with the top...

Страница 39: ...nderneath Attach the cartridge seal and it s o ring to the seal housing 4 bolts Apply the recommended torque to the bolts 1 02 Install the Cartridge Seal Housing to the seal housing with 4 bolts Align to match marks made from disassembly Torque bolts to specification 1 03 Use the extended shaft motor s integrated lifting features to raise the motor Carefully lower the motor into the cartridge seal...

Страница 40: ...Installation and Operation Manual SA 07 11 87 Rev A 35 January 2019 1 04 Install the 4 motor anchor bolts Continue to Assembly All Configurations for remaining installation steps page 38 ...

Страница 41: ...f 2 blocks allowing approximately 12 inches of clearance underneath Attach the cartridge seal and it s o ring to the seal housing 4 bolts Apply the recommended torque to the bolts 1 02 Using eyebolts or similar for lifting raise the bearing box assembly Carefully lower the bearing box assembly with the cartridge seal onto the seal housing ...

Страница 42: ...eration Manual SA 07 11 87 Rev A 37 January 2019 1 03 Bolt the bearing box housing to the seal housing using 4 bolts Torque to specification Continue to Assembly All Configurations for remaining installation steps page 38 ...

Страница 43: ...enter of the seal housing 1 02 Bolt 2 lifting brackets to the seal housing using 2 bolts per side finger tight each bracket is unique and must go on the correct side DO NOT TIGHTEN THE LIFTING BRACKET BOLTS YET NOTE Motor Bearing Box Cartridge Seal Housing Seal removed for clarity 1 03 Install the Lifting Hanger using 2 bolts nuts per side Tighten each size NOTE Motor Bearing Box Cartridge Seal Ho...

Страница 44: ...ended for anti rotation of the motor assembly 1 05 Secure the Lifting Hanger shackle to an overhead lifting devise to prevent the top assembly from tipping 1 06 Select any 4 locking screws of the Cartridge Seal Collar that are spaced 90 and tighten them in an alternating pattern from side to side until the screw makes contact with the shaft DO NOT tighten the screws at this time After the screws a...

Страница 45: ...ws Fully torque the screws to the manufacturer recommended torque listed on the seal drawing The screws can be torqued in a sequential order and the shaft can be turned to access the screws Note Insure all screws have been properly torqued before operating the pump Spacers must be repositioned or removed before operation Insure shaft turns freely 1 08 If the unit contains a throat bushing install ...

Страница 46: ...ngs or seals and tab washer at this time Note Left hand thread Note Restricting the shaft from moving will be necessary to tighten 1 11 Following Shim calculation install the diffuser cover shims impeller shims impeller impeller o ring inducer stud tab washer and inducer Note that the inducer stud is left hand thread turn counter clockwise to tighten Note For Cryogenic applications the seals used ...

Страница 47: ...off the crates using the Lifting Hanger shackle and an overhead lifting devise Carefully lower the top assembly down onto the pump case 1 13 Bolt the top assembly to the pump case with 14 nuts Apply Anti Seize to the stud threads and the face of the nut Torque the nuts per specification in a star pattern for even pressure distribution Remove the 4 lifting bracket bolts ...

Страница 48: ...Installation and Operation Manual SA 07 11 87 Rev A 43 January 2019 1 14 Install four seal guards 116D 116DA with screws 905G and washers 916BA to the pump assembly ...

Страница 49: ...m Fig 10 Impeller Clearance and Shim Locations Fig 11 Back Clearance Measurement Build the unit up to the installation of the impeller Section 1 10 of Assembly All Configurations but DO NOT install o rings at this time in the impeller and inducer Measure with feeler gages the clearance between the impeller and the upper cover at the outside diameter Measure in multiple places and use the lowest re...

Страница 50: ...lder wire and place it in the diffuser bowl about 1 0 25mm in from the outside diameter of the blade Lower the bearing box assembly into the diffuser pump case Tighten the assembly to 50 of the torque value with a minimum of four studs Remove bearing box assembly and the solder wire ring Measure the compressed thickness in several places Use the lowest reading Solder Ring ...

Страница 51: ...M 015 b If TC 120 is LESS than 0 negative value then SHIM 0 0 c If TC 120 is GREATER than 0 0 AND LESS than or equal to 015 then SHIM TC 120 3 For the Front Clearance FC the impeller is shimmed from the shaft a If the FC is LESS than OR Equal to 060 then SHIM 0 0 b If the FC is GREATER than 060 SHIM FC 060 Example 1 Existing Clearance Back 05 Front 065 TC 115 Logic Back TC 120 is LESS than 0 0 For...

Страница 52: ...al Shaft Prior to seal installation inspect the shaft splines for any sharp edges Remove sharp edges if necessary Cover the splines in masking tape before installation The shaft requires piston style sealing and when a spring energized seal is used it must be stretched to clear diameters that are in front of the seal gland The orientation is having the open part facing the opposite end of the shaf...

Страница 53: ... placement of this seal requires the use of a two step process 1 Stretch This is accomplished using a seal stretcher Insure no sharp edges reside along the corners Place tool on the end orient seal to Figure 13 then slide the spring energized seal over the tool spines and into groove No heating of seal or lubrication is required 2 Re sizer Once the seal in located in the groove use the resizer to ...

Страница 54: ...tion and Operation Manual SA 07 11 87 Rev A 49 January 2019 Figure 14 Spring Energized Seal Installation on Inducer Stretcher Inducer TO01MK05 Resizer Inducer TO01MK06 Seal Groove Stretch Tool Resizer Tool Seal ...

Страница 55: ...actually lower than NPSH requirement listed on specification sheet Suction line blocked check suction screen and valve Excessive pressure drop through suction piping Flow restricted by vapor pockets in high points of suction line Suction tank level or pressure too low Entrained air or vapor in pumped fluid NPSH reduced by presence of more volatile fluid in process fluid Failure of drive component ...

Страница 56: ...pening of the inlet area of the throat will result in higher flow rate and horsepower consumption Corrosion erosion of diffuser and cover surfaces will result in a significant horsepower increase Excessive recirculation from discharge to inlet Check flow through external plumbing Pump o ring 936C damaged or missing Integral centrifugal separator orifice worn Process fluid specific gravity or visco...

Страница 57: ...s can cause friction losses which will significantly increase horsepower consumption Clean these areas of all obstruction and restore surfaces to a smooth polished finish Check diffuser throat area at the inlet erosion or corrosion resulting in roughness or increased area will increase horsepower consumption Note A larger throat size than design will allow a higher flow and horsepower for a given ...

Страница 58: ...ER BOLTS 5 8 11 x 2 5 60 65 ft lbs 81 88 N m 905C HEX HEAD CAP SCREW CARTRIDGE SEAL BOLT 1 2 13 x 4 25 30 ft lbs 34 41 N m 905D HEX HEAD CAP SCREW BEARING BOX AND CARTRIDGE SEAL HOUSING TO SEAL HOUSING 5 8 11 x 1 5 60 65 ft lbs 81 88 N m 905E HEX HEAD CAP SCREW LIFTING BRACKET TO SEAL HOUSING 3 4 10 x 2 5 250 275 ft lbs 340 375 N m 905F HEX HEAD CAP SCREW LIFTING BRACKET TO LIFTING HANGER 3 4 10 x...

Страница 59: ...SOCKET HEAD CAP SCREW 3 13 DIFFUSER 1 909D HEX HEAD CAP SCREW 4 14A ALIGNMENT PIN 1 911 STUD 14 15 DIFFUSER COVER 1 914A HEX NUT 14 30 SEAL HOUSING 1 914H HEX NUT 4 60A CARTRIDGE SEAL 1 914K HEX NUT 4 116D SEAL GUARD 2 916A WASHER 14 116DA SEAL GUARD 2 916BA WASHER 8 118A CARTRIDGE SEAL HOUSING 1 916K WASHER 12 157A DIFFUSER COVER SHIM 1 916R WASHER 8 159A IMPELLER SHIM 1 936A O RING 1 700 LIFTING...

Страница 60: ...905K SOCKET HEAD CAP SCREW 6 14A ALIGNMENT PIN 2 906G SOCKET HEAD CAP SCREW 3 15 DIFFUSER COVER 1 911 STUD 14 15B COVER 1 914A HEX NUT 14 30 SEAL HOUSING 1 916A WASHER 14 60A CARTRIDGE SEAL 1 916S WASHER 4 68C LOCK NUT 1 916BA WASHER 8 68D LOCK WASHER 1 920E MOTOR KEY 1 68E GREASE RETAINER 1 924E PLUG 2 115A LOWER SEAL 1 924J NIPPLE 1 115B UPPER SEAL 1 936A O RING 1 116D SEAL GUARD 4 936B O RING 1...

Страница 61: ...Installation and Operation Manual SA 07 11 87 Rev A 56 January 2019 Extended Shaft Motor Configuration Figure 15 Extended Shaft Motor Configuration ...

Страница 62: ...Installation and Operation Manual SA 07 11 87 Rev A 57 January 2019 Bearing Box Configuration Figure 16 Bearing Box Configuration ...

Страница 63: ...Minimum Flow Conditions 16 Moving the Unit 20 Operating Conditions 6 Operation of Sundyne Pumps 16 Parallel Operation Control 15 17 Personal Protective Equipment 3 Piping Connections 5 Pre Commission Checklist 5 Pressurizing Fluid Loop 6 Pump Diagnostics 50 Pump Familiarization 5 Pump Removal from Pipe Work 19 Reassembling the LMV 803Lr 33 Seal Environmental Control System 10 11 Setting the Valves...

Страница 64: ... International S A 13 15 Blvd Eiffel B P 30 21604 Longvic Cedex France Phone 33 380 383300 Fax 33 380 383366 Sundyne HMD 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 3 4 925 51 16 00 ...

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