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Doc. ISM0076_MANUALE_CN SEAL-MV_ENG_REV04.DOCX

Setting Innovative

Standards

M PUMPS PROCESS SRL Via dell’artigianato, 120

45015 Corbola (RO) – Italia Tel. +39 0426 346304 Fax + 39 0426 349126 1

[email protected]

MECHANICAL SEAL PUMPS Centrifugal, Vertical, Inline

According to API610 – 11th edition

CN SEAL-MV series

User Manual

This copy of the manual is a translation of the italian version and both manuals must be always furnished together

MODEL: Bare Frame pump with motor

CAUTION These instructions are intended for operators: - Pump installation by qualified personnel; - Use the pump, by staff - Carry out maintenance / repair of the pump. Read this instruction manual before using the pump.

http://www.3mpumps.com/

Pag. 2/49 Doc. ISM0076_MANUALE_CN SEAL-MV_ENG_REV04.DOCX

Present instruction is valid for the pumps that have been supplied with, this is not for the total installation. Instruction and maintenance for the installation must be obtained from plant manufacturer, that designed the installation. In any case installation manual will take precedence over the pump manual. THIS INSTRUCTION MANUAL is intended to guide those responsible for the installation, operation and maintenance of M PUMPS PROCESS CN SEAL-MV series pumps. Please read it carefully, before you install and operate your M PUMPS PROCESS pump. Additional useful information can also be obtained contacting directly M PUMPS PROCESS or from: - Hydraulic Institute Standards (USA) regarding pump installation.

Doc. ISM0076_MANUALE_CN SEAL-MV_ENG_REV04.DOCX Pag. 3/49

Index 1. GENERAL WARNINGS AND SAFETY .............................................................................................................................. 5 2. SYMBOLS USED IN THE MANUAL .................................................................................................................................. 5 3. WARRANTY ................................................................................................................................................................... 6 4. NAMEPLATE ................................................................................................................................................................. 7 5. PUMP DESCRIPTION ................................................................................................................................................... 10

5.1. Applications ................................................................................................................................................................... 10 5.2. Technical Data............................................................................................................................................................... 10

6. ALLOWABLE NOZZLES LOADING ................................................................................................................................ 11 7. OPERATING LIMITS AND PERFORMANCES CN SEAL-MV SERIES.............................................................................. 13 8. OUTLINE DRAWINGS ................................................................................................................................................... 14 9. NOISE AND VIBRATION ............................................................................................................................................... 14 10. CHECKS TO PUMP DELIVERY, STORAGE .................................................................................................................... 14 11. SHIPPING AND HANDLING........................................................................................................................................... 14 12. LIFTING ....................................................................................................................................................................... 14 14. ASSEMBLY, INSTALLATION, CONNECTIONS, COMMISSIONING AND SETTING ............................................................. 15

14.1. Assembly ....................................................................................................................................................................... 15 14.2. Connection of the pump to suction and discharge pipes .................................................................................................... 15 14.3. Connection of the pump to suction and discharge pipes ................................................................................................... 15 14.4. Lubrication ..................................................................................................................................................................... 16 14.5. Checks for the proper operation ...................................................................................................................................... 20 14.6 Commissioning and operator training .............................................................................................................................. 20 14.7. Coupling of the pump to the motor .................................................................................................................................. 21 14.8. Features and installation of pump and motor assembly ..................................................................................................... 22 14.9 ALIGNMENT OF THE COUPLING ...................................................................................................................................... 22 14.10. Alignment tolerances and coupling .................................................................................................................................. 22 14.11. Alignment of Hot pumps ................................................................................................................................................. 22

15. INTENDED USE OF THE PUMP. IMPROPER USE. DESCRIPTION OF FUNCTIONING.PERSONAL PROTECTIVE EQUIPMENT DURING USE. ................................................................................................................................................ 23

15.1. Intended use of the pump .............................................................................................................................................. 23 15.2. Instructions for proper use reasonably foreseeable ........................................................................................................... 23 15.3. Not permitted use .......................................................................................................................................................... 23

16. RESIDUAL RISKS AND PROTECTION MEASURES TO BE TAKEN ................................................................................. 24 16.1. Description of the residual risks that remain..................................................................................................................... 24 16.2. Protection measures to be taken by the user and instructions ........................................................................................... 24 16.3. Personal protective equipment to wear ............................................................................................................................ 25

17. OPERATIONAL LIMITS, DESCRIPTION OF HAZARDS NOT EXCLUDED FROM THE SECURITY MEASURES TAKEN ..... 25 17.1. Safety information present on the pump .......................................................................................................................... 25

18. INSTRUCTIONS AND PROCEDURES FOR THE TRAINING OF THE PERSONEL AND FOR EMERGENCIES .................... 26 18.1. Recovery mode .............................................................................................................................................................. 26 18.2. Fire-fighting equipment to be used: ................................................................................................................................. 26 18.3. Emission / dispersion of harmful substances .................................................................................................................... 27

19. MALFUNCTIONING, FAILURE, BREAKDOWN, ACCIDENT. MOST FREQUENT PROBLEMS: CAUSES AND REMEDIES ... 27 19.1. Malfunctioning and Failure .............................................................................................................................................. 27 19.2. Breakdown .................................................................................................................................................................... 27 19.3. Accident ........................................................................................................................................................................ 27 19.4. Most frequent drawbacks: problems, causes, remedies, residual risks................................................................................ 27

20. PERIODIC AND EXTRAORDINARY MAINTENANCE ..................................................................................................... 31 20.1. Cleaning components ..................................................................................................................................................... 31 20.2. Periodic preventive maintenance ..................................................................................................................................... 31 20.2.1. Emptying of the fluid contained in the pump .................................................................................................................... 32 20.2.2. Draining the oil contained in the pump ............................................................................................................................ 32 20.3. Extraordinary maintenance ............................................................................................................................................. 32

21. REPAIR AND PARTS REPLACEMENT ......................................................................................................................... 32 22. The periodic maintenance specified in the“ PERIODIC AND EXTRAORDINARY MAINTENANCE” .............................. 33

22.1. Pump disassembling ....................................................................................................................................................... 33 22.1.1. Pull Out Element Removal .............................................................................................................................................. 34 22.1.2. Pull Out Element Disassembly ......................................................................................................................................... 35

23. EXAMINATION OF PARTS ........................................................................................................................................... 37 23.1. Cleaning Agents ............................................................................................................................................................. 37 23.1.1. Casing, seal housing and impeller ................................................................................................................................... 37 23.1.2. Mechanical seal .............................................................................................................................................................. 37 23.1.3. Throat Bush (If fitted) .................................................................................................................................................... 38 23.1.4. Shaft ............................................................................................................................................................................. 38


23.1.5. Gaskets and O-rings ....................................................................................................................................................... 38 23.1.6. Bearings ........................................................................................................................................................................ 38 23.1.7. Labyrinths or bearing isolators (if fitted) .......................................................................................................................... 39 23.2. Pump reassembling ........................................................................................................................................................ 39

24. DECOMMISSIONING, DISMANTLING AND DISPOSAL OF MATERIALS ...................................................................... 39 24.1. Decommissioning ........................................................................................................................................................... 39 24.2. Demolition and dismantling ............................................................................................................................................. 39

25. EXPLODED VIEW PART LIST ..................................................................................................................................... 40 26. NOTES ........................................................................................................................................................................ 44 27. APPENDIX A – Register of maintenance and periodic checks of the pump ................................................................ 45 28. APPENDIX B – Startup check list ................................................................................................................................ 46


1. GENERAL WARNINGS AND SAFETY

This manual was prepared by M PUMPS PROCESS pump to provide the buyer all necessary information for its proper use and regular maintenance. In this manual is also contained the manual of the electric motor when the pump is supplied with this. For safety and hygiene of the workplace and to ensure a fair and sustainable use of the pump, the manual should be kept for any consultation. As part of the pump, this manual must go with it. For any given non-deductible or not included in this manual is recommended that you contact M PUMPS PROCESS.

Do not use the pump before you have read and understood all safety rules and instructions in this manual. In case of damage or loss of the manual, ask for a copy to M PUMPS PROCESS promptly. The failure to follow instructions in this manual, exempt M PUMPS PROCESS from any liability. The pump and the instructions are intended for operators who make professional use and should be used by qualified personnel adequately trained, aware of uses, operation and risk that the pump generates during its use, the user with experience is the best form of qualification.

M PUMPS PROCESS reserves at any time the right to make changes deemed necessary to improve the pump, taking care to update this manual as soon as possible. This reflects the state of the art at the marketing pump. In case of transfer of the pump, the user is encouraged to report to M PUMPS PROCESS the address of the new owner to facilitate the transmission of any additions to the manual to the new user. M PUMPS PROCESS reserves all rights to this manual, no total or partial reproduction is allowed without written consent.

2. SYMBOLS USED IN THE MANUAL

In the text to indicate the risk of maneuvers or possible dangerous situations, warnings have been included, each of which consists of a symbol followed by a warning.

ELECTRICAL SAFETY

This symbol indicates electrical safety instructions where non-compliance will involve a high risk to personal safety or the loss of life.

LOSSES HAZARD

This symbol indicates safety instructions to follows during pump installation and commissioning where non-compliance will involve a high risk to personal safety or the loss of life.

HANDS HAZARD

This symbol is used in safety instructions to remind to don’t remove protections when pump is running. It is used in safety instructions where non-compliance in the hazardous


area would cause the risk of an explosion

ATEX

This symbol indicates explosive atmosphere zone marking according to ATEX 94/9/CE. It is used in safety instructions where non-compliance would cause the risk of an explosion in the hazardous area.

DANGER

Indicates a potential risk to operators who are using the pump and / or the integrity of the pump, which could result in damaging itself and / or serious injury to people concerned.

CAUTION

Calls attention to important details that the staff must know and keep in mind for the proper use and operation of the pump.

PROHIBITION Calls attention to transactions that are absolutely prohibited, not respecting the prohibition you may damage the pump and / or operators. M PUMPS PROCESS declines responsibility for damages to things or people for not having complied with the prohibitions set

3. WARRANTY

Valid for one year from the date of the pump sale. M PUMPS PROCESS do not assume any liability for any warranties explicit or implied, nor as regards the possibility to sell or the suitability of the items supplied. The warranty will not be applied if:

the repair and / or maintenance was not carried out strictly in accordance with the instructions;

the pump has not been installed and put into service as instructed, we strongly recommend to refer to APPENDIX B of the present manual for startup;

the repairs were not made by staff M PUMPS PROCESS or were made without consulting M PUMPS PROCESS;

spare parts are not original were used;

lubricants were used different from those recommended;

the parts supplied were not used according to their nature and / or destination;

the parts supplied were used carelessly, negligently, improperly;

the parts supplied were damaged due to external circumstances. All wear parts are excluded from warranty.


4. NAMEPLATE

The pump for installation in ordinary environments has the nameplate on the side of the support as shown: only the fields are compiled must be considered relevant and therefore valid for identification. -PUMP SUPPLIED WITH ELECTRIC MOTOR:


Pump serial number(s.nr) defines the type of components installed in the pump:


5. PUMP DESCRIPTION

CN SEAL-MV pump series is designed to meets the rigorous requirements of ISO 13709/API 610, eleven edition. A wide range of pump configurations and hydraulic coverage available. Vertical design ensure space-saving and suitability for cryogenic, high temperature and high working pressure services. ISO 21049/API 682 Seal Chamber accommodates a wide variety of seal configurations for the most severe services. A complement of ISO 13709/API 610 seal flush plans is available. Cartridge Seal Mounting assures ease of maintenance and precise seal face setting for maximum seal life Back Pull-Out of rotating assembly for OH3 models simplifies maintenance as neither the motor nor piping connections are disturbed. Motor Support Head is a heavy-duty design with a registered fit motor mount. Generous size open compartments allow easy access to all bolting and removal of the complete pumping assembly, including mechanical seal, without removal of casing. Dynamically Balanced Impeller limits vibration and assures smooth operation over wide flow range. Renewable Wear Rings for both the casing and impeller reduce replacement cost secured by axial screws, with option for tack welding, back wear ring standard and rear rings and balance holes eliminated for high suction pressure applications. Stiff Shaft Design limits maximum deflection at seal faces to 0.05 mm(0.002 in) maximum for a long life of the pump.

5.1. Applications

Generally this model is ideal for clean liquids slightly contaminated, without particles that can be magnetized;

The maximum working pressure of the plant, the allowable temperature and the maximum rotation speed depends on the type of pump and it is specified in the "TECHNICAL DATA" paragraph. Other uses are not allowed as the conditions of use stated in the “TECHNICAL DATA” paragraph must be respected in full. Using the pump in a plant or in liquid conditions different from those for which the pump was designed, can lead to dangerous situations to the user.

5.2. Technical Data

The pump described in this manual has the following characteristics: CN SEAL-MV

Nozzle: ANSI B 16.5 - 300lbs or DIN PN 40 flanged, other on request;

Max viscosity: 200 cps (standard);

Max system pressure: 40 bar (standard, CN SEAL-MV); higher pressure rating available, please refer

to pump datasheet;

Flow up to 1800 mc/h;

Head up to 155 m;

Working temperature up to +350 °C;

Installed motor power: from 1,5 kW to 500 kW;

Speed: up to 3500 rpm (up to 6x4x13, superior sizes up to 1750 giri/min );

Weight (pump only): from 55 to 1800 kg;

Electric Motor characteristics: Supply frequency: 50 Hz Supply frequency: 60 Hz

2 poles 2900 rpm 3500 rpm



CAUTION CAUTION: If the pump is driven by inverter, remain within the recommended limits

of rotation


6. ALLOWABLE NOZZLES LOADING

Following table shows nozzles loading of CN SEAL-MV pump series in standard execution. For Special construction please refer to GA drawing sent.

PUMP SIZE

Fx; N Fy; N Fz; N Fr; N Mx; Nm My; Nm Mz; Nm Mr; Nm

Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch.

2x1½x5 1420 1420 1780 1780 1160 1160 2560 2560 920 920 460 460 700 700 1240 1240

2x1½x6 1420 1420 1780 1780 1160 1160 2560 2560 920 920 460 460 700 700 1240 1240

2x1½x8 1420 1420 1780 1780 1160 1160 2560 2560 920 920 460 460 700 700 1240 1240

2x1½x10 1420 1420 1780 1780 1160 1160 2560 2560 920 920 460 460 700 700 1240 1240

3x1½x5 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x1½x6 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x1½x8 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x1½x10 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x1½x13 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x2x5 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x2x6 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x2x8 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x2x10 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

3x2x13 2140 1420 2660 1780 1780 1160 3860 2560 1900 920 940 460 1440 700 2560 1240

4x3x5 2840 2140 3560 2660 2320 1780 5120 3860 2660 1900 1360 940 2000 1440 3600 2560

4x3x6 2840 2140 3560 2660 2320 1780 5120 3860 2660 1900 1360 940 2000 1440 3600 2560

4x3x8 2840 2140 3560 2660 2320 1780 5120 3860 2660 1900 1360 940 2000 1440 3600 2560

4x3x10 2840 2140 3560 2660 2320 1780 5120 3860 2660 1900 1360 940 2000 1440 3600 2560

4x3x13 2840 2140 3560 2660 2320 1780 5120 3860 2660 1900 1360 940 2000 1440 3600 2560

6x3x6 4980 2140 6220 2660 4100 1780 8960 3860 4600 1900 2360 940 3520 1440 6260 2560

6x3x8 4980 2140 6220 2660 4100 1780 8960 3860 4600 1900 2360 940 3520 1440 6260 2560


PUMP

SIZE Fx; N Fy; N Fz; N Fr; N Mx; Nm My; Nm Mz; Nm Mr; Nm

Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch. Suct. Disch.

6x3x10 4980 2140 6220 2660 4100 1780 8960 3860 4600 1900 2360 940 3520 1440 6260 2560

6x3x13 4980 2140 6220 2660 4100 1780 8960 3860 4600 1900 2360 940 3520 1440 6260 2560

6x3x16 4980 2140 6220 2660 4100 1780 8960 3860 4600 1900 2360 940 3520 1440 6260 2560

6x4x6 4980 2840 6220 3560 4100 2320 8960 5120 4600 2660 2360 1360 3520 2000 6260 3600

6x4x8 4980 2840 6220 3560 4100 2320 8960 5120 4600 2660 2360 1360 3520 2000 6260 3600

6x4x10 4980 2840 6220 3560 4100 2320 8960 5120 4600 2660 2360 1360 3520 2000 6260 3600

6x4x13 4980 2840 6220 3560 4100 2320 8960 5120 4600 2660 2360 1360 3520 2000 6260 3600

6x4x16 4980 2840 6220 3560 4100 2320 8960 5120 4600 2660 2360 1360 3520 2000 6260 3600

6x6x8 4980 4980 6220 6220 4100 4100 8960 8960 4600 4600 2360 2360 3520 3520 6260 6260

6x6x10 4980 4980 6220 6220 4100 4100 8960 8960 4600 4600 2360 2360 3520 3520 6260 6260

6x6x13 4980 4980 6220 6220 4100 4100 8960 8960 4600 4600 2360 2360 3520 3520 6260 6260

6x6x16 4980 4980 6220 6220 4100 4100 8960 8960 4600 4600 2360 2360 3520 3520 6260 6260

8x6x10 7560 4980 9780 6220 6220 4100 13840 8960 7060 4600 3520 2360 5160 3520 9420 6260

8x6x13 7560 4980 9780 6220 6220 4100 13840 8960 7060 4600 3520 2360 5160 3520 9420 6260

8x6x16 7560 4980 9780 6220 6220 4100 13840 8960 7060 4600 3520 2360 5160 3520 9420 6260

8x6x20 7560 4980 9780 6220 6220 4100 13840 8960 7060 4600 3520 2360 5160 3520 9420 6260

10x8x10 10680 7560 13340 9780 8900 6220 19260 13840 10040 7060 4880 3520 7600 5160 13500 9420

10x8x13 10680 7560 13340 9780 8900 6220 19260 13840 10040 7060 4880 3520 7600 5160 13500 9420

10x8x16 10680 7560 13340 9780 8900 6220 19260 13840 10040 7060 4880 3520 7600 5160 13500 9420

10x8x20 10680 7560 13340 9780 8900 6220 19260 13840 10040 7060 4880 3520 7600 5160 13500 9420

12x10x13 13340 10680 16000 13340 10680 8900 23400 19260 12200 10040 5960 4880 9220 7600 16420 13500

12x10x16 13340 10680 16000 13340 10680 8900 23400 19260 12200 10040 5960 4880 9220 7600 16420 13500

12x10x20 13340 10680 16000 13340 10680 8900 23400 19260 12200 10040 5960 4880 9220 7600 16420 13500

14x12x16 14240 13340 17800 16000 11560 10680 25560 23400 12740 12200 6240 5960 9500 9220 17080 16420

14x12x20 14240 13340 17800 16000 11560 10680 25560 23400 12740 12200 6240 5960 9500 9220 17080 16420


7. OPERATING LIMITS AND PERFORMANCES CN SEAL-MV SERIES


8. OUTLINE DRAWINGS

Please refer to specific documentation, supplied with the present manual.

9. NOISE AND VIBRATION

The pump noise depends primarily on the operating conditions. The operating condition of the pump during the measurements is: the coupling of the pump with the electric motor on the bench with pumping fluids. The A-weighted sound pressure level to front and side of the pump is below 85 dB (A). When pump noise level exceeds 85 dBA attention must be given to prevailing Health ans Safety legislation, to limit the exposure of operating personnel to the noise. An enclosure can be adopted to reduce emitted sound.

10. CHECKS TO PUMP DELIVERY, STORAGE

All M PUMPS PROCESS pumps are tested before shipment and carefully packed for transport: at the reception of the pump make sure that the pump has not been damaged during the transport. If there are problems, contact immediately the carrier and inform M PUMPS PROCESS about what happened. So that the pump is preserved over time as best as possible, we recommend storing it away from the sun, bad weather and dust, if not immediately installed or used for long periods. Stoppers closing the input and output connections of the fluid must not be removed until installation. If provided with electric motor, observe also the motor manufacturer’s storage formality. The maximum allowable temperature range during storage, preservation and use must be between -15 e +40°C with humidity between 10 e 90%.

11. SHIPPING AND HANDLING

You should carry out a precautionary check of the pump at the receiving to detect and report any damage in the transport and handling operations. In case of breakages contact immediately M PUMPS PROCESS. The precautions to ensure the stability of the pump concern the possible slips and overturning caused by handling and transport, which must be prevented by setting the pump casing of the pump with ropes to the vehicle frame. Pump and motor assembly cannot be moved manually due to its high weight. To move a pump positioned on a pallet, enlarge as maximum as possible the forks and then operate. For a stable lifting the pump can be lift as indicated in the figures:

12. LIFTING

For a stable lifting the pump can be lift as indicated in the figures:

Bare frame pump without motor Bare frame pump with motor

Centre of gravity approximately in the middle Centre of gravity approximately in the middle


These operations must be performed by a trained staff who is informed of the risk of these proceedings.

FORBIDDEN It is forbidden to lift the pump using different lugs from the ones specially designed and reported, as points of anchorage.

You cannot lift a pump and motor assembly using the eye-bolt of the electric motor only.

During the lifting the entire surrounding area is considered as a danger zone and must be cleared by personnel not engaged in those operations.

It is indicated the possibility of transporting and handling the pump using the lugs designed for that use: you must ensure that chains and shackles are able to withstand the weight of the pump (as shown in "TECHNICAL DATA").

14. ASSEMBLY, INSTALLATION, CONNECTIONS, COMMISSIONING AND SETTING

14.1. Assembly

Install the pump on a solid foundation as close as possible to the liquid to be pumped, below the level, in a position to facilitate maintenance and inspection. Ensure that the pump doesn’t take rough shacks as this may damage the magnets of the internal and external rotor or the silicon carbide bearings. Ensure that the heated air from other units does not affect the pump; the air temperature must not exceed 40 °C, for higher temperatures contact your distributor M PUMPS PROCESS; ensure also the free circulation of air cooling of at least ¼ the engine diameter, because either the pump or the motor should be able to dissipate the heat by natural air convection. Insufficient cooling could lead to high surface temperatures of the bearings seat, poor lubrication and premature failure of bearings. Useful is the monitoring of the surface bearings’ temperature. It is always responsibility of the operator to keep low the temperature of the liquid so that not to superheat the pump: in case of irregular pressure fluctuations and flow drop turn off the pump.

CAUTION Normally you should mount the pump horizontally. If mounted vertically or inclined, the pump, or rather the suction flange shall be placed in the lowest point. Leave a space of at least 50 cm between the pump and any walls or pipes.

Vertical pumps cannot be installed horizontally or inclined.

When pumping liquid can reach high temperatures: form 60 °C upwards you must install protections to prevent contact with hot pump parts;

Connect to the ground the entire pump casing to prevent accumulation of static electricity;

If the pumped liquid can be dangerous to people and environment, the user must take precautions for a simple and quick block in case of leakage for breakage/ replacement/ pump maintenance.

14.2. Connection of the pump to suction and discharge pipes

For a proper assembly aimed at an optimal use of the pump, you must follow these requirements:

pipes must be supported and kept in line regardless of the pump, until its connections, so that not to impose on it;

links must not be subjected to stresses during the job ;

the maximum permissible forces and moments on flanges shall not exceed those listed in “technical data”;

inlet pipes should be constructed with as few restrictions as possible in order to have the highest available NPSH;

the length of pipes , particularly that of the inlet pipe must be minimized;

the pipe must be placed so that it is not possible the formation of air; if this is not possible, it should be calculated the possibility of bleeding the air from the highest point ;

during suction use full section valves only;

14.3. Connection of the pump to suction and discharge pipes


14.4. Lubrication

Three options are available for bearings lubrication, - grease, - oil mist - oil cascade inside bearing housing. Ball-Bearings Lubrication by Grease Before placing the pump in operation, it must have grease supplied to the thrust bearings, the line bearing is life greased. Unplug the grease outlet plug located opposite the fitting in the bearing housing outer cover. Pump grease into the fitting in the bearing housing outer cover until grease just begins to extrude from the grease outlet. Replug the grease outlet and turn the shaft several times by hand to distribute the grease in the bearings. Thereafter, re-grease thrust bearings at 3000 hour intervals of operation. Refer to Section 5.2.1 for proper grease type.

Pure Oil Mist Lubricated Ball-Bearings Ensure that oil mist system is installed on the pump bearing housing and is operating. Please refer to manufacturer’s instructions. No additional information is necessary.


Oil Lubricated Ball-Bearings Preparation of bearing housing Bearing frame must be carefully cleaned before filling with oil. It is also good practice to flush it with oil, compatible with the lubricating oil that will be used. The reservoir is to be filled to appropriate level as illustrated in the picture below. The oil level must be maintained at the correct level: decreasing of oil level may cause overheating and failure of the bearings, while exceeding the correct level can result in leakage. The constant level oiler can be adjusted by changing the height of the cross arms which support the glass reservoir, as illustrated for TRICO oiler below.


Trico oiler setting (standard)

a) Initial fill via top of housing, using overflow plug to establish correct level (refer to the picture above b) Release thumb screw and remove bottle. Establish a measurement from the center line of the oiler

connection in bearing housing to the upper cross arm of amounts indicated in the following table this can be obtained by completely screwing down constant level oiler lower arm.

c) Fill bottle with recommended oil and install on holder. Remove and fill bottle as many times as is required to fill the bearing housing up to the cross arm level and no air bubbles appear in the bottle.

d) Remove bottle and ascertain that the oil level is is desired, shown in the table below,from the center line of oiler connection. Adjust upper cross arm as required and lock in place with lower arm.

Inspection Inspect the oil level in the bearing housing and the condition of the oil at least weekly. Oil is always subject to progressive deterioration from use and contamination from dirt and moisture which is the cause of premature bearing wear. For oil lubricated pumps, fill the bearing housing with correct grade of oil to the correct level, i.e. constant level oiler bottle (standard configuration) and sight glass (when fitted on request).

Replenishment Replenish the oil in the oiler as required. More frequent replenishment at high temperatures may be required. Oil change Frequency of oil change is dependent on pump service and environmental conditions. As a general guide, oil in the bearing housing should be changed every 4000 operating hours, after the initial change. Lubrication Specification The ideal bearing lubricant is a straight well refined, neutral mineral, preferably of the turbine type. It should not contain free acid, chlorine sulphur or more than a trace of free alkali. It is suggested that the oil conform to the following physical characteristics.


Oil quantity in bearing house

PUMP RANGE PUMP SIZE OIL QUANTITY [Liter] ARM

SETTINGS [mm]*

OIL LEVEL FROM THE BOTTOM

OILER [mm]*

2^ RANGE

2x1½x10

0.525 16 30

3x1½x10

3x1½x13

3x2x10

3x2x13

4x3x6

4x3x8

4x3x10

6x3x6

6x3x8

6x3x10

6x4x8

4^ RANGE

8x6x13

1.40

8x6x16

8x6x20

10x8x10

10x8x13 16 30

10x8x16

10x8x20

12x10x13

5^ RANGE 12x10x16

2.69 24 26 12x10x20

*WE CONSIDER THE STATIC CONDITION AFTER A PROPER PERIOD FOR COMPLETE OIL LEVELLING BETWEEN OILER AND BEARING FRAME

Connection of the pump to suction and discharge pipes For a proper assembly aimed at an optimal use of the pump, you must follow these requirements:

pipes must be supported and kept in line regardless of the pump, until its connections, so that not to impose on it;

links must not be subjected to stresses during the job ;

the maximum permissible forces and moments on flanges shall not exceed those listed in “technical data”;

inlet pipes should be constructed with as few restrictions as possible in order to have the highest available NPSH;

the length of pipes , particularly that of the inlet pipe must be minimized;

the pipe must be placed so that it is not possible the formation of air; if this is not possible, it should be calculated the possibility of bleeding the air from the highest point ;

during suction use full section valves only;


NO SI

- if the suction tube was larger than the suction flange, you will use an eccentric reduction, in order to prevent formation of air and turbulence;

- if there is a possibility that the maximum working pressure can be overcome, for example due to excessive suction pressure, you should take appropriate measures by including a safety valve in the pipe;

- Avoid using quick-closing valves, because sudden changes of pressure cause water hammer very dangerous for the pump and the pipes;

- Before installing the pump, make sure the suction line is clean and/or provided with a filter to protect the impeller and the stationary bearings from damages incurred by slag, or other foreign particles , especially when you start the installation for the first time.

Electrical connections:

DANGER

The pump is provided with or without electric motor: only qualified personnel should carry out mechanical connection of the pump to the motor (for the model without motor) and the electrical connections of the motor to the electrical system. Please read carefully the instructions of the manufacturer of the motor or the manual before you complete the installation.

Make sure that the motor doesn’t start during maintenance jobs.

14.5. Checks for the proper operation

We recommend installing a pressure gauge on both inlet and outlet pipes to allow the operator to easily control the proper pump functioning in relation to the required operating point: in case of cavitation or other malfunctions, there will be obvious pressure fluctuations. Check the differential pressure of the pump between the suction and discharge connections to verify that it works in the point of work provided. Check that the absolute pressure at suction is not so low to cause the cavitation.

CAUTION The absolute pressure at pump suction (m) must be at least 0,5 to 1 m, the vapour pressure of the pumped liquid, in order to avoid cavitation. Cavitation should always be avoided as it is very dangerous for the structure of the pump. Do not dry run the pump!

Commissioning and operator training

With regards to the proper commissioning, starting and controls to be carried out before, during and after the first start, please refer to APPENDIX B, which must be filled and returned to M PUMPS to activate product warranty.


The M PUMPS PROCESS series CN SEAL-MV are not reversible so the rotation cannot be reversed. The proper direction is clockwise. If you put in front of the pump casing, an arrow indicates the correct direction of rotation; to reverse the direction of rotation may cause damages to the pump. To control the direction of rotation, give and immediately remove voltage, then observe the direction of rotation.

ROTATION SENSE:

Make sure that rotating parts, such as flexible coupling or other related organs, are always protected when the pump is running.

Operators using the pump must have read this manual in the sections committed to the functioning, use and maintenance, as well as being qualified to fully understand the features and to be able to identify the problems of the pump. By carrying out the functions mentioned in the previous section and all controls listed in APPENDIX B and in the maintenance register, the pump is ready for use.

14.6. Self-priming pumps and non-self-priming pumps

CN SEAL-MV pumps are not self-priming: Make sure that the pump is always filled with the pumping liquid to avoid any damage. Use a back flow check valve to stop reverse flow when operating with suction lift, dry run should be avoided.

14.7. Coupling of the pump to the motor

If pump and motor have to be coupled, respect the following sequences to proceed with the installation:

Fit the two elastic coupling halves on the pump and the motor.


- Place the motor, insert thicknesses (about 5mm), under motor flange, so that the two shafts (pump and

motor) are coaxial.

- Leave a space of 3mm between the two elastic coupling halves, and then block the motor with the

provided screws.

-

14.8. Features and installation of pump and motor assembly

The shafts of the pump and the motor have already been adjusted and aligned as an extension of one another. For installation of the plant it is necessary to respect the sequence of actions:

- The base plate must be affixed to an horizontal plane, using also thickness; - Tighten the nuts of the bolts; - Check the shafts alignment and the motor alignment and repeat these actions if necessary (described in

the paragraph “Alignment of the coupling”)

14.9. ALIGNMENT OF THE COUPLING

Place a straight edge on the coupling. Insert or remove any thickness necessary to bring the

motor at the correct height, so that the bottom edge of the ruler is placed on both halves of the

coupling for the entire length;

Repeat the same check on both sides of

the coupling, at the height of the shaft.

Turn the motor shaft so that the bottom

edge of the straight edge touches both

halves of the coupling for the entire

length;

Reinstall coupling guard.

14.10. Alignment tolerances and coupling

The maximum allowed tolerances for the two halves alignment of the coupling, to be verified with the

comparator, are:

TYPE OF COUPLING OFFSET ANGLE

Short flexible coupling

(3000 rpm)

0.05mm 0.04mm for coupling with

diameter 100mm.

Flexible coupling with

spacer (3000 rpm)

0.07mm for spacer 100mm. 0.04mm for coupling with

diameter 100mm.

Flexible coupling with

spacer (3000 rpm)

0.07mm for spacer 300mm. 0.04mm for coupling with

diameter 200mm.

14.11. Alignment of Hot pumps

When operation of a pump at less than, or greater, than 20°C temperature would cause alignment

changes due to thermal effects on the pump's pedestal position, final alignment must be made with the

pump and driver at their actual operating temperature; else there can be no assurance that pump and

driver are in alignment while operating. Driver temperature change from ambient to operation

temperature will also affect alignment. A hot check can only be made after the unit has been in


operation a sufficient length of time to assume its NORMAL operating temperature and conditions. If

the unit has been correctly cold set, parallel misalignment will be within 0.05 mm (0.002 in.) TIR and

the angular misalignment will be within 0.025 mm (0.001 in.) when in operation. If not make

adjustments.

15. INTENDED USE OF THE PUMP. IMPROPER USE. DESCRIPTION OF FUNCTIONING.PERSONAL PROTECTIVE EQUIPMENT DURING USE.

15.1. Intended use of the pump

The pump works correctly if the parameters specified in the APPENDIX B and paragraphs

“TECHNICAL DATA” are followed.

15.2. Instructions for proper use reasonably foreseeable

Before starting work you must check that:

All maintenance actions were properly carried out according to the time intervals set by M PUMPS

PROCESS;

There are no damaged parts of the pump;

All the warning stickers and safety licence plates are present and in good condition and are operating the

emergency stop buttons (check through a test).

CAUTION At the start, immediately check the pressure gauge placed in the discharge: if the

discharge pressure reaches the nominal value quickly, stop the pump and try

staring. Check the pump and piping to make sure that there is no leakage of liquid

from the plant. A noisy pump is a symptom of a malfunction that represent a

failure in the short term. A very low frequency and with a rumbling can indicate

the state of cavitation; an excessive noise of the motor can be caused by a wear of

a bearing.

15.3. Not permitted use

While maintaining the conditions of use indicated in the paragraph “TECHNICAL DATA”, the ways in

which the pump should not be used are given here. To avoid damaging the pump, it is forbidden to use it

in the following conditions:

PROHIBITION Start the pump dry: the pump casing must be full of liquid.

Run the pump dry for more than 1 minute;

Mare the pump work with inlet valve and /or outlet closed: the heat

generated by the impeller, by mechanical seal and bearings will boil

the liquid, which will cause pump cavitation/vibration, the impeller

damaging and the bearings collapse;

The pump flow should never be adjusted by the valve located in the

suction pipe, which must be kept fully open, start and or make the

pump work if there are losses;

Start the pump if there are losses;

Change working condition of the pump without having consulted

the M PUMPS PROCESS Technical Office;

Loosen the pump connections while under pressure;


Try to clean the pump while it is running;

Run the pump in the opposite direction to that shown in the pump

casing;

Run the pump over nominal temperature and pressure;

Pumping liquids containing solid particles of any size, without

written consent of M PUMPS PROCESS or substances that can

attack chemically or erode the inside of the pump;

Remove guards and shelters while the pump is running;

Act on electrical parts installed without first removing the tension,

not to alter the safety devices installed, do not activate repeatedly

the command buttons.

DANGER It is incorrect any use of the pump other than that mentioned in the paragraph

“Instructions for a proper use reasonably foreseeable”.

M PUMPS PROCESS disclaims any liability damages to things and people related

to uses for which the pump was not specifically designed and constructed.

Also the ways in which certain situations of danger might present as a result of improper use, are

prohibited.

16. RESIDUAL RISKS AND PROTECTION MEASURES TO BE TAKEN

16.1. Description of the residual risks that remain

Despite adopted measures incorporated in the pump, the main dangers associated with the use of the

pump and the solutions identified are the followings:

Danger of sketches projection of process fluid that can be corrosive or burning, as a result of improper

installation and sudden ruptures of the pump casing and hydraulic lines;

Danger of cuts to the hands due to the presence of smears on the pump casing;

Explosion of the pump is due to a formation of explosive mixture inside the pump casing as a result of

an improper use.

16.2. Protection measures to be taken by the user and instructions

PROHIBITION It is absolutely forbidden to the user to tamper with safety devices. Before

using the pump check the proper couplings mechanical protection. Any tampering

nullifies the warranty and liability of M PUMPS PROCESS towards the pump

users.

Only maintenance personnel can perform maintenance operation affecting safety devices.


16.3. Personal protective equipment to wear

Protection measures that have to be taken during this phase are adopting antacid and antistatic coverall,

chemical-resistant glasses, gloves to protect from mechanical and chemical agents and safety shoes.

Avoid the use of accessories (necklaces, bracelets, etc.) and clothes unshackled; torn or dangling that

could get entangled in parts of the structure.

17. OPERATIONAL LIMITS, DESCRIPTION OF HAZARDS NOT EXCLUDED FROM THE SECURITY

MEASURES TAKEN

Dangers that have not been reduced/ eliminated with the security measures adopted on the pump can be

reduced/eliminated if operators apply measures on management as a result of having to:

Keep all the safety warnings of and all plaques and labels intact and replace them when

necessary, periodically checking their good condition;

Don’t employ substances which may affect the physical ability or the mental faculty (alcoholic

beverages, medicines, drugs, etc);

Don’t use without permission spare parts not identical to the originals or components not

approved by M PUMPS PROCESS;

Don’t perform any modification or structural intervention without the approval of M PUMPS

PROCESS;

After shocks accidentally suffered by the pump, check the pump integrity and perform a check to

M PUMPS PROCESS;

After a long period of pump detention check the pump integrity and functionality of stakeholders

to wear. If necessary perform the replacement with identical spare parts to the originals.

CAUTION Each of the misuse or negligence listed here causes:

immediate cancellation of M PUMPS PROCESS assistance.

cancellation of M PUMPS PROCESS responsibility for damage to property,

animals or people.

17.1. Safety information present on the pump

Safety warnings applied to the pump must be respected and restored in case of illegibility, and are as

follow:

Warning Description signs applied Symbol/indication Quantity Notes

1. Marking plate M PUMPS

PROCESS.

As described in paragraph

“PLATE” 1 1

2. Label “follow IOM

instructions”

1 /

3. Label “Fill with oil prior to

start”

1 /


Warning Description signs applied Symbol/indication Quantity Notes

4. Label “check correct pump-

motor alignment prior to start“

1 /

2. Label rotation and not run dry

indication

1 2

3. Hydro-test label

1 3

4. Label quality control assembly

1 Internal use

18. INSTRUCTIONS AND PROCEDURES FOR THE TRAINING OF THE PERSONEL AND FOR EMERGENCIES

Operators responsible for the various life stages of the pump must be:

- For assemblers: staff formed and trained on good practices for handling of goods with the use of tools

and lifting equipment;

- For installers of pipes and electrical connections: qualified and trained staff to operate on electrical

plants, staff with experience in hydraulic installations;

- For users: professional staff trained in the instruction for use of this pump.

In case of emergency:

- Alert who is close to the situation of danger, even waving his arms;

- Stop the pump by pressing the nearest emergency stop button;

18.1. Recovery mode

To return to normal operating conditions, you must delete all the causes that have generated the

emergency, possibly repairing or replacing the components that caused the failure.

CAUTION

After the intervention of security devices, you must find the cause of action before

continuing operations.

18.2. Fire-fighting equipment to be used:

In case of fire involving the pump, you can use water or foam liquid only after removing the voltage, or

a powder type fire extinguisher with extinguishing agent. Do not use CO2 as being launched at -79 ° C

may react violently with hot parts.


18.3. Emission / dispersion of harmful substances

The fluid in the plant might be released in the atmosphere following an intervention or the pump break.

19. MALFUNCTIONING, FAILURE, BREAKDOWN, ACCIDENT. MOST FREQUENT PROBLEMS:

CAUSES AND REMEDIES

There aren’t pump details which provide such cases of malfunctioning as to restrict or make its use

dangerous.

In paragraph “Most frequent drawbacks: causes and remedy” is discussed with more details in this

section.

19.1. Malfunctioning and Failure

In case of failure of mechanical parts you must immediately restore the original terms of security by

replacing or repairing the parts that have deficiencies.

In case of failure of the pump, proceed as follows:

- Turn the motor off;

- Close the inlet and outlet valves;

- Find the cause of the failure by checking the section “ Most frequent drawbacks: problems,

causes, remedies, residual risks".

The failure of a pumping plant can be attributed to:

- A pump failure;

- A failure or defect in the pipe;

- A failure due to an installation or a start not correctly executed;

- A a wrong choice of pump.

19.2. Breakdown

In the event of failure of pump alert verbally the staff present in the nearness of the damage that is

verifying.

19.3. Accident

In case of accident, you must report the emergency to the plant responsible for the installation, in order

to secure the plant to reach with the emergency team the place where the accident happened.

19.4. Most frequent drawbacks: problems, causes, remedies, residual risks

INSUFFICIENT FLOWS

Causes Remedies / actions to be taken

The head requested exceeds the pump

head expected.

Reduce the total head of the system if possible.

Increase the diameter of the discharge pipe.

Check that the discharge valve is fully open.

Replace the pump.

Consult M PUMPS PROCESS.


The head requested is lower than pump

head expected.

Increase the diameter of the discharge pipe.

Replace the pump.


Insufficient speed Consult M PUMPS PROCESS.

Excessive Suction lift Check that NPSHa>NPSHr, suction line losses on

strainer and fittings

The pump rotates in the opposite

direction.

Check the direction of rotation.

Refer to section 13.5 of this manual

Air or steam trapped in the suction. Check the presence of air or steam trapped. Check

suction line design.

Air leaks in the suction line Check suction pipe is airtight

Air leaks into pump through mechanical

seal, sleeve joints, casing joint or pipe

plugs

Check and replace with new all damaged or worn parts,

consult M PUMPS PROCESS.

Foot valve undersized or partially

clogged

Check foot valve.

Suction pipe inlet not sufficiently

submerged

Consult system designer

The liquid contains air or steam. The

liquid produces foam.

Check the presence of vortices in the suction line. Enter

some in the fuel tank to prevent the formation of

vortices. Install a tank of sufficient capacity in the

suction line to allow gas to drag.

Insufficient inlet pressure, with the

generation of cavitation and loss of

efficiency.

Increase the static height at the suction.

Check that the intake is not blocked or are no

bottlenecks. Reduce the liquid temperature. Increase the

diameter of the intake pipes.

Reduce the length of inlet pipes. Open completely the

inlet valve. Check the viscosity of the liquid; refer to

"technical data" section of this manual, increase the

temperature of the liquid if necessary.

Wear ring, wear pump casing or

impeller.

Check the condition of rotating ring wear and collar.

Replace if worn; refer to Chapter 10 of this manual.

The temperature of the liquid is close to

boiling point

Reduce the liquid temperature.

Viscosity of liquid different from design Consult M PUMPS PROCESS.

NO FLOW

Causes Remedies / actions

The pump is defused Re-prime the pump. Refer to section 13.3 of this

manual. Check for air leaks in the suction line

Suction line blocked Ensure that there are no blind pipes, obstructed or

valves closed.







submerged


Insufficient speed Consult M PUMPS PROCESS.

The motor stopped Check the power of the motor. Check the status of the

motor.

EXCESSIVE FLOW


The head required is lower than that

provided by the pump

Reduce the speed of rotation, if possible; reduce the

impeller diameter; partially close the discharge valve.

OVERHEATING OR MOTOR STOP

Excessive pumped liquid density Reduce the flow by closing the valve outlet partially

The pump is defused Re-prime the pump. Refer to section 13.3 of this

manual. Check for air leaks in the suction line

Operating at very low flow Check that flow is superior than minimum permitted.

The pump has seized or is about to seize.

Check the free rotation of the impeller. Check for

internal obstructions.

The motor and pump are misaligned

Refer to section 14.1 of this manual

The motor bearings are damaged or

worn.

Replace the motor bearings, investigate the causes of

breakage.

Motor under dimensioned Mount a more powerful motor (check in advance with

your distributor M PUMPS PROCESS ).

Motor overload threshold set incorrectly Check the security settings of the motor

The guard against the motor dry running

(where present) has failed or has been

set incorrectly.

Control flow decreases or fluid intake.

FUNCTIONING WITH NOISE DEFECTS AND/OR

VIBRATIONS


Insufficient inlet pressure, consequent

cavitation, insufficient lubrication of the

bearings (with mechanical damages if

the condition persists).

STOP IMMEDIATELY THE PUMP!

Refer to paragraphs 13.2 to 13.8 manual






Foot valve undersized or partially

clogged

Check foot valve.




submerged


Operating at very low flow Check that flow is superior than minimum permitted.

Operating at high flow Check that flow is superior than maximum permitted.

Unbalanced Impeller. Consult M PUMPS PROCESS.

Wear of the coupling motor-pump Replace the coupling and proceed to the realignment of

pump and motor.


submerged


Ball bearings or motor failure. Check and replace them if necessary.

Uninsured motor or base plate. Make sure that the motor and base plate are firmly

anchored to foundations and do not produce any

abnormal vibration.

Misalignment or improper anchoring of

the pipes.

Check correct alignment of pipes and supports, refer to

section 14.1 of this manual.

The pump was started while still rotating

in the opposite direction, for a previous

start.

Stop immediately the pump and drain all the liquid

from the discharge line before restarting.

OVERHEATING OF EXTERNAL BEARINGS (bare shaft versions)

Lack of oil or wrong type of oil in the

bearing frame.

Check the oil level: fill up or empty, and replace it if

necessary. Replace the bearings.

Excessive oil temperature into the bearing

frame.

Fill the bearing frame with oil as indicated in the

paragraph to restore the correct working temperatures.

MECHANICAL SEAL LEAKS EXCESSIVELY

Misalignment due to strain from pipes. Check connections and eliminate any strains using

elastic coupling or other permitted method. Support

pipes.

Shaft bent. Check shaft runouts are within acceptable values.

Bearing failure or worn. Check bearings and replace it in case of failure or

worn.

Leakage under sleeve due to joint failure. Check possible damages and replace joint.

Mechanical seal improperly installed. Check alignment of faces or damaged parts and

investigate assembly method adopted.

Wrong mechanical seal type respect

operating condition. Consult M PUMPS PROCESS.

Unbalanced Impeller.


Presence of abrasive particles into

pumped liquid.

Mechanical seal dry running.

Internal misalignment after repair Carefully check repair method.


20. PERIODIC AND EXTRAORDINARY MAINTENANCE

Proper maintenance and use are essential factors to ensure the functionality and pump lifetime.

20.1. Cleaning components

To clean all surfaces of the pump and centering surfaces, use possibly methyl alcohol. Use paper towels

instead. Do not use solvents and other corrosive liquids to avoid damaging it;

20.2. Periodic preventive maintenance

Instructions relating to maintenance activities whose implementation do not require specific skills that

can then be made by users of the pump, are given. They are operations and inspections planned on

issues considered important for technical, operational and security staff, determined on the basis of the

knowledge gained from M PUMPS PROCESS. If the hydraulic pump is washed with jet in pressure,

prevent the entry of water into the terminal of the motor.

DANGER Do not throw water on the pump hot components: components can explode in case

of sudden cooling generating projection of metallic material and leakage of hot

fluid in pressure and hazardous to health. Do not give strokes and pressures on the

bearings, you would cause the formation of micro-cracks which can cause serious

damages.

N.

Description control /

intervention: implementation

rules

Warnings and protective measures

be taken to perform the

maintenance properly and safely

Time

1 Ball bearing frame Top up the oil until the middle of

the eye plug

Weekly. Replace oil

every 5,000 hours.

2 Internal bearings Check the status of bushings,

sleeve bearings and thrust

bearings,

replace them if worn

After 2500 hours,

check any premature

wear, then every

5,000hours or every

year.

3 Wear rings Check the status of the wear ring,

consult the table of tolerances

After 2500 hours,

check for premature

wear, then every

5000 hours or every

year.

4 Motor bearings Unless other specifications, motor

bearings are greased for life, so

there is not a maintenance

schedule, anyway it is

recommended to check the

condition of the bearings and

replace them when worn


N.

Description control /

intervention: implementation

rules


be taken to perform the

maintenance properly and safely

Time

RECOMMENDED: (TABLE OILS for ambient temperatures exceeding 15 ° c, by classification ISO VG 68)

BP HPL 68

CHEVRON EP industrial oil 68

Texaco Rando Oil HDC 68

TOTAL Azolla 68

Shell Tellus 68

Mobil DTE Heavy Medium ISO 68

STATOIL HYDRAWAY HV 68

Esso Teresso 68 / AGIP OSO 68

CAUTION

In Appendix A is a list of periodic maintenance and inspections to be completed each time you perform

such operations.

20.2.1. Emptying of the fluid contained in the pump

Before disassembling, you must empty the liquid from the pump according to the following steps:

Close the valves present in the inlet and outlet pipes, and in the cooling pipe;

Unscrew the drain plug;

When emptied, screw the drain plug again.

If hazardous to health liquids are pumped, wear suitable personal protective equipment.

20.2.2. Draining the oil contained in the pump

If the pump is lubricated with oil (bare shaft versions):

Remove the oil drain plug;

Drain the oil and collected it without dispersing into the environment;

Replace the drain plug .

If there are fluids hazardous to health, wear personal protective equipment suitable before coming into

contact with the liquid.

20.3. Extraordinary maintenance

The extraordinary maintenance operations concern the activities that are beyond those typically

programmable and executable; they require precise technical expertise by qualified personnel, and then

you should contact M PUMPS PROCESS. Delivery is the one shown in the back cover of this manual.

DANGER If it becomes necessary to disassemble the pump, you must remember that the

liquid should be collected and disposed in accordance to existing environmental

laws. If the pump should be sent to M PUMPS PROCESS it must be drained, and

should not contain any traces of liquid pumped.

21. REPAIR AND PARTS REPLACEMENT

The pump must always be kept in optimum conditions of operation.

Most of the spare parts have clear and comprehensive references for their identification. It is important

that the spares are replaced by similar ones so that they can be considered equivalent in quality and


safety: to order original spare parts, contact M PUMPS PROCESS referring to the model of the pump,

employee number, description of the component and the quantity needed.

When you see elements with rust, cracks, etc, you must perform all replacements/repairs necessary to

re-establish the conditions of the pump safe working. In any case you should always ask an opinion M

PUMPS PROCESS before any intervention.

22. The periodic maintenance specified in the“ PERIODIC AND EXTRAORDINARY MAINTENANCE”

To allow a smooth running for a long time is necessary to make the required maintenance.

Operators should make frequent visual inspections to check that the pump is running smoothly without

noise or vibration, and that the discharge pressure is holding steady, without fluctuation, at the correct

figure. Over-heating of the pump or motor bearings is cause for alarm. The bearing housing should not

be more than 50°C above ambient temperature, nor should it exceed 80°C (too hot to touch) in any

event. If the bearings overheat, shut the pump down immediately, investigate the cause, and take

corrective action.

22.1. Pump disassembling

If the pump has pumped hot liquids, make sure that it has been cooled before disassembly. The pump

may have pumped liquid hazardous to health is therefore necessary to wear personal protective

equipment.

Before to proceed with disassembling, follow carefully the decommissioning instructions, at paragraph

20.2.

The activities of disassembly and maintenance of the pump should be conducted in full compliance with

current health and safety regulations. Some spare parts may have potential health risk to the operators:

DANGER

Refer to Safety paragraph of the present manual prior to start any maintenance

activity.

CAUTION M PUMPS PROCESS disclaims any liability for damage to property and people and

will invalidate the warranty if you install non original.

Please refer to following cross section for part numbers and relative identification.

Before to disassemble the pump assembly, the pump must be isolated from the system closing suction

and discharge plant valves, drained of liquid and cooled, if pump is handling hot liquid.

Before attempting any maintenance work on pumps in vacuum service, the pumps must be isolated from

suction and discharge system then carefully vented balance pressure in pump casing to atmospheric

pressure.

Remove the pipe plug(s) from the top of the bearing housing(s) and check to see that oil rings are riding

free on the pump shaft and are not hung up.

CAUTION Failure to observe this caution could result in damage to or destruction of


equipment.

22.1.1. Pull Out Element Removal

This pump has a pull-out element, which consists of the pump shaft (12), mechanical seal assembly

(21), casing cover (9), impeller (7), and bearing housing assembly, as well as their attached

parts. This pull-out element makes it unnecessary to remove the driver, motor bracket (6), or casing

(1) to service the bearing housing assembly, mechanical seal (21), impeller (7), wear rings

(8.1/8.2–3.1/3.2), stuffing box bushing (10), and gaskets.

a) Remove all mechanical seal piping, instrumentation and electrical device that can disturbs

disassembly. Pump casing has to be drained.

DANGER When pump is handling "hot" liquid extreme care must be taken to ensure safety of

operators that drain the pump . Hot pumps must be allowed to cool before

draining.

DANGER When pump is handling "caustic" liquid extreme care must be taken to ensure

safety of operators when removing auxiliary piping or when draining pump.

Protective devices of suitable protective materials must be worn when draining the

pump.

b) Remove coupling guard (33) from bearing frame (32) by removing bolts and washers.

Remove bolts and nuts holding the guard together, then remove the guard.

c) Disassemble and remove coupling spacer in accordance with the manufacturer’s instructions supplied

with the present manual.

d) In case of Oil Lubrication drain the bearing frame of oil removing draining plug (34) at the bottom of

the bearing housing.

DANGER Use caution when draining hot oil from bearing housing to prevent burns/injury to

personnel

e) Remove the hex bolts clamping the casing cover (9) to the casing (1).

f) Use the jacking bolts provided on the casing cover (9) flange to lift the cover from the casing (1) and

raise the cover above the lower flange of the support head (6).

g) Attach the pullout element lifting arm to the pullout element, then lift the element out of the casing

(1). (See figure 6.2).


Fig. 6.2

The lifting arm is not supplied with the pump. It must be ordered apart.

h) Raise the pullout element upward until the impeller clears the lower flange of the support head (6)

and remove through the large opening in the support head.

i) Remove the casing cover gasket (16) from the casing (1) or casing cover (9) and discard.

j) Move the pullout element to a safe, clean work area for further disassembly.

22.1.2. Pull Out Element Disassembly

All gaskets and O-rings removed during maintenance are to be discarded and replaced with new ones to

ensure proper sealing during subsequent operation.

As a reminder of the orientation of the casing cover and the bearing housing you might match mark

these parts before separating them;

however, the OUTLINE drawing shows the factory orientation.

To disassemble the pullout element, soft cable (or equivalent) and lifting equipment should be handy

and used for heavy parts. Proceed as follows:

a) Secure bearing housing (32) to workbench in a position that will allow impeller (7) and casing cover

(9) to be pulled away from shaft (12) and bearing housing (32).

b) Secure shaft (12) to prevent rotation.

The impeller cap nut (20) is left hand threaded. To remove the impeller cap nut, turn it to the right

(clockwise) while facing the impeller.

c) Untight the security dowel of the cap nut (20) and remove it from shaft.

d) Use heat, if necessary, on impeller (7) and remove it from shaft.

e) Remove impeller key (18.2).

f) Install the mechanical seal spacers to lock the shaft sleeve to the seal plate. Then loosen the set screws

which hold the shaft sleeve to the shaft.


g) Unscrew cap screws that hold bearing housing (32) to casing cover (9) and tap casing cover and

bearing housing with mallet to break cover loose from housing.

The impeller cap nut (20) is left hand threaded. To remove the impeller cap nut, turn it to the right

(clockwise) while facing the impeller.

h) Hold shaft sleeve in place and carefully slide casing cover (9) with sleeve and mechanical seal parts

off shaft and clear of bearing housing (32).

The stuffing box bushing (10) is pressed into the casing cover (9) and should not be removed unless

worn or badly scratched or gouged, in which case the old bushing must be pressed out and a new one

pressed in.

i) Set casing cover (9) on workbench with bearing-housing side up.

To disassemble a mechanical seal follow the seal manufacturer's instructions in the Appendix.

j) Remove the seal plate nuts and the mechanical seal (21).

k) If no pumpage has got into bearing housing and you plan to replace just the mechanical seal, omit the

remaining steps; otherwise continue to disassemble pump as outlined.

l) Evenly heat pump half-coupling using a welding torch with a Rosebud head until you are able to pull

half-coupling off with a coupling puller, then remove half-coupling and key (18.1).

m) Remove outboard fan (28.1) and O-rings (27.1). Loosen screw on inboard fan (28.2) and slide off

shaft.

n) Unscrew bearing housing end cover cap screws (29.1) and slide it off shaft, with the labyrinth seal

(5), remove the O-ring (27.1).

Now it is possible to extract bearing labyrinth seal (5) and replace it in case of worn or damage.

CAUTION Although not necessary, it may be worthwhile to lift the bearing housing and block

it in a vertical position with the thrust bearing up to facilitate removal of the shaft

and bearings. Support shaft as it is moved out of bearing housing by soft cables and

hoist or wood blocks.

p) Remove shaft (12), with thrust bearings (15) and radial bearing (14) installed, from bearing housing

(32).

q) Proceed as follows:

• If your pump is grease or pure mist lubricated, then slide the labyrinth seal (29.1) and O-ring (27.2) off

of the shaft (12).

• If your pump is oil lubricated, then loosen the set screws which hold the screw pump to the shaft, then

slide the screw pump (30) off of the shaft.

r) Place shaft in a vice which is covered with a soft material such as copper to prevent marring; then

clamp it just enough to keep it from turning when thrust bearing lock nut (26) is broken loose.

s) Bend back tab on thrust bearing lock washer (25). Unscrew thrust bearing lock nut (26).


Facing the bearing nut, turn it clockwise to loosen. Remove lock nut and lock washer from shaft.

t) Remove shaft from vice and press bearings (15 – 14) off shaft with hydraulic press, if available;

otherwise, leave shaft in vice and pull bearings off shaft with a bearing puller. Slide the deflector ring

(23) off of the shaft.

u) If your pump is oil lubricated: The inner bearing housing cover (29.2) should only be removed if

there is evidence of leakage. If the cover is to be removed, remove the cap screws and slide the cover

out of the bearing housing.

23. EXAMINATION OF PARTS

Used parts must be inspected before assembly to ensure the pump will subsequently run properly.

In particular, fault diagnosis is essential to enhance pump and plant reliability.

To perform a good visual inspection and to obtain the highest degree of cleanliness, which is essential to

the correct fit and balance of all rotating parts, the shaft must be stripped of all parts. The visual

inspection consists of examining the following parts for those conditions that commonly impair pump

operation. Where the corrective action may not be apparent to a journeyman millwright or a more

extensive examination is required, the inspection item is cross-referenced to a detailed procedure.

Unless noted below, all damaged parts should be replaced rather than repaired.

23.1. Cleaning Agents

When the pump is used in the steam generator feed, the boiler feed, the reactor feed, or other such steam

(or water) circuit, all internal metal parts of the pump including the case should be cleaned with a

nonpetroleum-base cleaning agent such as alcohol or acetone or a steam cleaner that uses steam from

demineralised water. The basic concern should be to insure that the solvent is compatible with the

pumpage. Petroleum-base agents such as dry cleaning solvent and kerosene may be used for cleaning

internal parts when such agent will dissolve in the liquid being pumped without inducing an ill effect.

Petroleum-base agents should be used to clean the bearings and their housings.

Fumes from alcohol, acetone, petroleum solvents and other such chemicals are injurious to health and

may ignite from a spark; make certain that the area where they are used is well ventilated and have a fire

extinguisher handy.

23.1.1. Casing, seal housing and impeller

a) Inspect for erosion, foreign object damage and cracks; erosion and damage must be corrected before

final assembly.

b) Inspect impeller cap nut (20) and impeller (7) for nicks, gouges, galling and rust. c) Inspect impeller

bore for correct fit with shaft (See Section 6.9.2 ”Checking Fit Between Impeller Bore and Shaft”).

d) Inspect running surfaces of stuffing box bushing (10), shaft (12), case wearing ring (3.1),

casing cover wearing ring (3.2), and impeller wearing rings (8.1–8.2) for nicks, burrs, scratches,

scouring and excessive wear.

Concentric and smooth surfaces are required (See Section 6.9.1 “Wear Rings”).

e) Replace as necessary.

23.1.2. Mechanical seal

a) Mechanical seal stationary and rotating faces should be inspected for signs of wear or cracks and

replaced as necessary.


b) It is recommended that when reassembling mechanical seal new "O" rings and gaskets be used.

c) Refer to manufacturers drawing for assembly of mechanical seal. Refer to mechanical seal section

within this manual for further details.

23.1.3. Throat Bush (If fitted)

a) Check the throat bush and replace if required.

Note that the bush outside diameter should be the same diameter as the adjacent impeller wear ring.

23.1.4. Shaft

Shaft (12) for scratches, nicks, burrs, and distortion; absolutely smooth surfaces and a straight shaft are

required.

After the shaft is inspected for damage as described above, it must be checked for straightness before

reassembling the rotating parts. When making the check do not turn the shaft in its lathe centers. It is

possible for the lathe centers of a straight shaft to be off center slightly, resulting in a false indication of

a

bent shaft.

1. Set shaft in soft-faced V-blocks, precision rollers (or equivalent).

2. Check straightness by taking dial indicator readings all along the shaft while it is rotated; total runout

of shaft must not exceed 0.04 mm (0.0015 in). If runout is exceeded shaft must be coldstraightened or

replaced.

Application of heat to straighten shaft will cause more distortion.

The term "soft-faced V-blocks" refers to V-blocks faced with metal that is softer than the shaft, for

example, V-blocks faced with copper.

23.1.5. Gaskets and O-rings

After dismantling, discard and replace.

23.1.6. Bearings

a) It is recommended that bearings are not re-used after any removal from the shaft. In any case the

bearings must be replaced not after 25000 operating hours.

b) If the bearing cannot be removed with the tools available never use a torch under any circumstances.

Split the outer ring with a small hand grinder, saw through the ball/roller retainer, and split the inner

ring about three quarters through with a grinder and break with a cold steel chisel.

Do not attempt to inspect condition of bearings until they have been cleaned.

c) Solvent for cleaning bearings should be in a clean container. Place bearings in solvent and let soak for

a short time. Agitate the bearing around near the top of the container, giving it a turn now and then until

it is clean. Rinse in a clean container of fresh solvent.

Do not spin dirty bearings. Rotate them slowly while washing.

d) Dry thoroughly cleaned bearings. If an air hose is used for drying, make sure it is clean dry air.

Do not allow the bearings to spin by force of air. Hold the inner and outer rings to prevent bearing from

spinning.


e) Inspect bearings immediately. If there is any question as to the condition of a bearing do not hesitate

to replace it. There are many conditions that contribute to the deterioration of the bearings. A qualified

bearing representative should be consulted if there is any question of bearing condition.

f) Inspected bearings which will be reused should be packed with new grease or dipped in clean

lubricating oil, covered with clean lint free rags or other suitable covering and placed in a clean box or

carton until ready for installation.

Under no circumstances the bearings are to be left exposed.

23.1.7. Labyrinths or bearing isolators (if fitted)

a) The lubricant, bearings and bearing housing seals are to be inspected for contamination and damage.

If oil bath lubrication is utilised, these provide useful information on operating conditions within the

bearing housing.

b) If bearing damage is not due to normal wear and the lubricant contains adverse contaminants, the

cause should be corrected before the pump is returned to service.

c) Labyrinth seals and bearing isolators should be inspected for damage but are normally non wearing

parts and can be re-used.

d) Bearing seals are not totally leak free devices.

Oil from these may cause staining adjacent to the bearings.

23.2. Pump reassembling

To reassemble the pump, follow maintenance procedure (enclosed…..) in reverse order. Clean each

component before assembly; make sure that all parts are free from dirt, metallic particles, etc.

24. DECOMMISSIONING, DISMANTLING AND DISPOSAL OF MATERIALS

24.1. Decommissioning

For an eventual long time decommissioning, it is advisable to apply some simple precautions to preserve

correctly the pump.

Make the pump run with clean water (or other suitable solvent compatible with the materials of the

pump) for several minutes, in order to avoid the risk of liquid precipitation or deposits. Disconnect from

the electric power / liquid supply and place it in a protected site.

During the commissioning after a long period of stocking, carefully follow all recommendations for

commissioning described at paragraph 3.5 of this manual.

CAUTION A good stocking will guarantee against unpleasant incidents during the restarting of

the pump. M PUMPS PROCESS disclaims any responsibility for machines stored

incorrectly. If you intend to stop using this pump it is recommended to make it

inoperative.

24.2. Demolition and dismantling

The user must comply with the legislation on environmental conservation and will have to deal with the

disposal and elimination of materials and harmful substances of the pump components. It is

recommended to destroy the identification plates of the pump and any other document.


25. EXPLODED VIEW PART LIST

PART LIST

N° DESCRIZIONE DESCRIPTION

1 Corpo pompa Pump casing

2 Piastra base corpo pompa Baseplate pump casing

3.1 Anello usura corpo pompa Pump casing wear ring


4.1 Prigioniero Stud nut




5 Garlock Labyrinth seal

6 Supporto motore Bracket

7 Girante Impeller

8.1 Anello usura girante Impeller wear ring


9 Cassastoppa Stuffing box

10 Bussola di findo fissa Fixed bushing

11 Tubo ricircolo olio Flushing pipe

12 Albero Shaft

13 Bussola di findo rotante Rotary bushing

14 Cuscinetto a sfere Ball bearing

15 Cuscinetto a sfere obliquo Oblique ball bearing

16 Guarnizione Gasket

17.1 Dado Nut

17.2 Dado Nut

18.1 Chiavetta Key

18.2 Chiavetta Key

19 Rosetta di sicurezza Security washer

20 Ogiva Impeller nut

21 Tenuta meccanica Mechanical seal

22 Tappo sfiato Vent plug

23 Anello lancia olio Lubricating disk thrower

24 Oliatore a livello costante Constant level oiler

25 Rosetta della ghiera Lockwasher

26 Ghiera di bloccaggio Lock ring

27.1 O-ring O-ring

27.2 O-ring O-ring

27.3 O-ring O-ring

28.1 Ventola Fan

28.2 Ventola Fan

29.1 Coperchio cuscinetti Bearing cover


30 Bussola pompante Pumping bushing

31 Lanterna cassa olio Bearing frame lantern

32 Cassa olio Bearing frame

33 Coprigiunto Coupling guard

34 Tappo drenaggio olio Draining plug


PART LIST

N° DESCRIZIONE DESCRIPTION

1 Corpo pompa Pump casing

2 Piastra base corpo pompa Baseplate pump casing






5 Ventola Fan


6 Supporto motore Bracket

7 Girante Impeller



9 Cassastoppa Stuffing box

10 Bussola di findo fissa Fixed bushing

11 Coprigiunto Coupling guard

12 Albero Shaft

13 Bussola di findo rotante Rotary bushing

14 Cuscinetto a sfere Ball bearing

15 Cuscinetto a sfere obliquo Oblique ball bearing

16 Guarnizione Gasket

17.1 Dado Nut

17.2 Dado Nut

18.1 Chiavetta Key

18.2 Chiavetta Key

19 Rosetta di sicurezza Security washer

20 Ogiva Impeller nut

21 Tenuta meccanica Mechanical seal

22 Tappo sfiato Vent plug

23 Lanterna cassa olio Bearing frame lantern

24 Cassa olio Bearing frame

25 Rosetta della ghiera Lockwasher

26 Ghiera di bloccaggio Lock ring

27.1 O-ring O-ring

27.2 O-ring O-ring

28.1 Deflettore Deflector

28.2 Deflettore Deflector




26. NOTES


27. APPENDIX A – Register of maintenance and periodic checks of the pump

It is provided a list of maintenances to be carried out and their respective ranges; you must register these

operations.

Commissioning date: ____________________

Main maintenance operations to be performed by the second year of use onwards:

N. Required check


be taken to perform maintenance

properly and safely

Range

1 Check oil level at bearing frame Top up the oil until the middle of

the eye plug

Weekly. Replace

the oil every 5000

hours.

2 Internal bearings Check the condition of bushings,

sleeve bearings and thrust bearing

if worn replace them, reassemble

using new gaskets

After 2500 hours,

check any

premature wear,

then every 5,000

hours or every

year.

3 Wear ring Check the status of the wear ring,

see the table of tolerances

After 2500 hours,

check any

premature wear,

then every 5,000

hours or every

year.

4 motor bearings Unless other specifications, motor

bearings are greased for life, so

there is not a maintenance

schedule, anyway it is

recommended to check the

condition of the bearings and

replace them when worn

DATE

DESCRIPTION OF OPERATION

(report the numbers associated with intervention and any operations

carried out in addition)

OPERATOR

SIGNATURE


APPENDIX B – Startup check list

PUMP SERIES CN SEAL-MV

- Do not destroying – do not modify - Rev. N°00

Date 21/02/2013

STARTUP CHECK LIST This document consists of 2 pages

Nr. Description of activity YES /

NO /

*UPON ARRIVING CHECKS:

1 Check Pump Name Plate , Motor Name plate to tally with PO and Data Sheet

2 Any Cracks or damages to Pump or motor during shipment or handling

3 Check accessories if ordered to tally with PO

4

Are Installation, Operation and Maintenance Manuals for Pump, Motor and Coupling supplied?

5

Have you received the Pump Curve, GA Drawing, Pump Data Sheet, Motor Data Sheet and Wiring Diagram?

6 Have you read through and understand the IOM manuals?

*INSTALLATION CHECKS:

1 Has the Pump's baseplate being properly level and firmly secured?

2 Has the Pump and motor coupling being secured and aligned?

3

Are Suction and Discharge Pipe line with Flexible Joints being Supported and Secured?

4 Any undue Pipe loading onto Pump inlet/Outlet Nozzle due to Mis-alignment

5 Is Suction Strainer being installed to protect the Pump?

6

Are Suction and Discharge Pressure Gauge being installed before Pump's Inlet and Outlet?

7 Is there any Check Valve being installed at Pump's discharge Outlet?

8 Has the Power supplied for Electrical Motor being connected by qualified electrical personnel?


9

Have the Pump Bearings been filled with recommended Lubricating Oil and to the stated level (For Long Coupled Pump)?

10 Have the motor Bearings been greased if required?

* PRE START-UP

1

For High /Low Temperature Pumping application , has the pump been warmed up to required Temperature?

2 Can the Pump shaft turns freely by hand?

3 Fully Open the Suction Valve.

4 Partially Open the Discharge.

5 Ensure Suction line is Filled and the Pump been Primed of entrained Air.

6 Jog Start the motor, Verify that the direction of rotation is correct.

* AFTER START-UP

1

Start the pump set and be sure that the discharge pressure is building up( stop the pump if discharge pressure is not building up in short time and check the possible causes

2

Throttle or Set Discharge Valve to designed Duty Point. (Pressure and Flow Rate)

3

Reading of Suction Pressure ( ) Discharge Pressure ( ) and Flow Rate ( ).

4 Are the Suction and Discharge Pressure Gauge Stable?

5

Check Pump bearing and motor bearing temperatures are stabilized below 82 deg C.

6 Amperage reading does not exceed nameplate full load amps plus S.F.

7 Checked no abnormal temperature and leakage.

8 Checked no abnormal pump vibration and noise.


9

Under Normal Condition, continuously run the pump under observation for one or two hours.

COMMENTS/REMARKS:

INSTALLATION REFERENCE:

PROJECT: CONTACT:

CONTRACTOR:

ADDRESS:

PHONE NO: FAX:

PUMP MODEL NO: SERIAL NR:

MOTOR TYPE: IMPELLER

DIAMETER:

START-UP BY: FOLLOW UP

REQD:

DATE: SIGNATURE:

Please send this document, duly completed, to the e-mail: [email protected], or by FAX at: +39 0426 349126


M PUMPS PROCESS S.R.L. Sede Legale: Via Milite Ignoto, 51 – 45019 – Taglio di Po – (RO) – Italy Sede operativa: Via dell’Artigianato, 120 - 45015 Corbola (RO) – Italy Tel.: +39 0426 346304 Fax: +39 0426 349126 E-mail: [email protected]

mailto:[email protected]

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