PUMPIRAN PB3 Montageanleitung

PB3 centrifugal pumps

Multistage, double suction, horizontally split, centrifugal pump

Doc. No.:

These Operating Instructions Contain Fundamental Information

&Precautionary Notes. Please Read The User Instruction Prior To Installation

Of Unit, Electrical Connection & Commissioning. It is Imperative to Comply

with All Other Operating Instructions Referring to Components of Individual

Units.

Installation

Operation

Maintenance

User Instruc

ion

PB3 User Instruction

Page 2 of 39

CONTENTS

PAGE

1. INTRODUCTION AND SAFETY 4

1.1 General 4

1.2 CE marking and approvals 4

1.3 Disclaimer 4

1.4 Duty conditions 4

1.5 Safety 5

1.6 Noise level 7

2 TRANSPORT AND STORAGE 8

2.1 Consignment receipt and unpacking 8

2.2 Handling 9

2.3 Lifting 9

2.4 Extended storage 11

2.5 Recycling and end of product life 14

3 INSTALLATION 14

3.1 Location 14

3.2 Foundation 14

3.3 Grouting 15

3.4 Initial alignment 16

3.5 Piping 20

3.6 Electrical connections 23

3.7 Final shaft alignment check 24

3.8 Protection systems 24

4 COMMISSIONING, START-UP, OPERATION AND SHUTDOWN 25

4.1 Precommissioning procedure 25

4.2 Pump lubrication 27

4.2.1 Lubricating oil 27

4.3 Direction of rotation 28

4.4 Guarding 28

PB3 User Instruction

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4.5 Priming and auxiliary supplies 29

4.6 Starting the pump 29

4.7 Running or operation 29

4.8 Stopping and shutdown 30

4.9 Hydraulic, mechanical and electrical duty 31

5 MAINTENANCE 32

5.1 Maintenance schedule 33

5.2 Spare parts 33

5.3 Recommended spares and consumable items 34

5.4 Fastener torques 35

6 FAULTS; CAUSES AND REMEDIES 36

7 DRAWINGS AND PARTS LIST 38

PB3 User Instruction

Page 4 of 39

1. INTRODUCTION AND SAFETY

1.1 General

WARNING

These Instructions must always be kept close to product's operating

location or directly

with the product.

PUMPIRAN's products are designed, developed and manufactured with state-of-the-art technologies in modern

facilities. The unit is produced with great care and commitment to continuous quality control, utilizing

sophisticated quality techniques, and safety requirements.

PUMPIRAN is committed to continuous quality improvement and being at service for any further information

about the product in its installation and operation or about its support products, repair and diagnostic services.

WARNING

These instructions are intended to facilitate familiarization with the product and its

permitted use. Operating the product in compliance with these instructions is important to

help ensure reliability in service and avoid risks.

These instructions must be read prior to installing, operating, using and maintaining the

equipment. The equipment must not be put into service until all the conditions relating to

safety, noted in the instructions, have been met.

1.2 CE marking and approvals

Where applicable, the Directives and any additional Approvals, cover important safety aspects relating to

machinery and equipment and the satisfactory provision of technical documents and safety instructions. Where

applicable this document incorporates information relevant to these Directives and Approvals.

1.3 Disclaimer

Information in these User Instructions is believed to be reliable. In spite of all the efforts of PUMPIRAN

to provide sound and all necessary information the content of this manual may appear insufficient and is

not guaranteed by PUMPIRAN as to its completeness or accuracy.

PUMPIRAN manufactures products to exacting International Quality Management System Standards as

certified and audited by external Quality Assurance organizations. The failure to properly select, install or use

authorized PUMPIRAN parts and accessories is considered to be misuse. Damage or failure caused by misuse is

not covered by PUMPIRAN's warranty.

1.4 Duty conditions

This product has been selected to meet the specifications of your purchase order. The acknowledgement of these

conditions has been sent separately to the Purchaser.

WARNING

The product must not be operated beyond the parameters specified for the

application. If there is any doubt as to the suitability of the product for the

application intended, contact PUMPIRAN for advice, quoting the serial number.

PB3 User Instruction

Page 5 of 39

1.5 Safety

1.5.1 Summary of safety markings

These user instructions contain specific safety markings where non-observance of an instruction would cause

hazards. The specific safety markings are:

Symbol Description

This symbol indicates electrical safety instructions where non-compliance will involve

a high risk to personal safety or the loss of life.

This symbol indicates safety instructions where non-compliance would affect personal

safety and could result in loss of life.

This symbol indicates “hazardous substances and toxic fluid” safety instructions where

noncompliance would affect personal safety and could result in loss of life.

This symbol indicates safety instructions where non-compliance will involve some risk

to safe operation and personal safety and would damage the equipment or property.

This symbol indicates explosive atmosphere marking according to ATEX. It is used in

safety instructions where non-compliance in the hazardous area would cause the risk of

an explosion.

This symbol indicates is used in safety instructions to remind not to rub non-metallic

surfaces with a dry cloth; ensure cloth is damp. It is used where non-compliance in the

hazardous area would cause the risk of an explosion.

This sign is not a safety symbol but indicates an important instruction in the assembly

process.

1.5.2 Personnel qualification and training

All personnel involved in the operation, installation, inspection and maintenance of the unit must be qualified to

carry out the work involved. If the personnel in quetion do not already possess the necessary knowledge and

skill, appropriate training and instruction must be provided. If required the operator may commission the

manufacturer / supplier to provide applicable training.

1.5.3 Safety action

This is a summary of conditions and actions to prevent injury to personnel and damage to the environment and

to equipment. (For products used in potentially explosive atmospheres section 1.6.4 also applies.)

Caution

Ensure correct lubrication.

Caution

Prevent excessive external pipe load. Do not use pump as a support for piping. Do not

mount expansion joints, unless authorized by Pumpiran in writing, so that their force,

due to internal pressure, acts on pump flange.

PB3 User Instruction

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Caution

Start the pump with outlet valve partly opened (Unless otherwise instructed at a specific

point in the user instructions). This is recommended to minimize the risk of overloading

at full flow and damaging the pump at zero flow.

Pumps

may

be started with the valve

further open only on installations where this situation cannot occur. The

pump

outlet

control valve may need to be adjusted to comply with the duty following the run-up

process. (See section 4, Commissioning start-up, operation and shutdown.)

- Never run the pump dry.

Caution

- Inlet valves to be fully open when pump is running.

- Running the pump at zero flow or below the recommended minimum flow

continuously will cause damage to the pump and seals.

- Low flow rates may cause a reduction in pump/bearing life, overheating of the

pump, instability and cavitation/ vibration.

Caution

Do not run the pump at abnormally high or low flow rates.

Operating at a flow rate higher than normal or at a flow rate with no backpressure on the

pump may overload the motor and cause pump cavitation.

DANGER

Never do maintenance work when the unit is connected to power.

hazardous substances and toxic fluid

When the pump is

handling hazardous

liquids care must be taken to avoid exposure to

the liquid by appropriate sitting of the pump, limiting personnel access and by operator

training. If the liquid is flammable and/or explosive, strict safety procedures must be

applied

HANDLING COMPONENTS

Many precision parts have sharp corners and the wearing of appropriate safety gloves

and equipment is required when handling these components. To lift heavy pieces above

25 kg use an appropriate crane for the mass and in accordance with current local

regulations.

THERMAL

SHOCK

Rapid changes in the temperature of the liquid within the pump will cause thermal

shock, which can result in damage or breakage of components and should be avoided.

PB3 User Instruction

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HOT (and cold) PARTS

If hot or freezing components or auxiliary heating supplies can present a danger to

operators and persons entering the immediate area action must be taken to avoid

accidental contact. If complete protection is not possible, the machine access must be

limited to maintenance staff only, with clear visual warnings and indicators to those

entering the immediate are. Note/; bearing housings must not be insulated and drive

motors and bearings may be hot.

If the temperature is greater than 68 °C (154°F) or below -5 °C (20 °F) in a restricted

zone, or exceeds local regulations, action as above shall be taken.

1.5.4 Products used in potentially explosive atmospheres

explosive atmosphere

Measures are required to:

- Avoid excessive temperature

- Prevent the buildup of explosive mixtures

- Prevent the generation of sparks

- Prevent leakages

- Maintain the pump to avoid hazard

The following instru

tions for pumps and pump units when installed in potentially explosive atmospheres must

be followed to help ensure explosion protection.

Both electrical and non-electrical equipment must meet the requirements of European Directive 94/9/EC.

1.6 Noise level

Attention must be given to the exposure of personnel to the noise, and local legislation will define when

guidance to personnel on noise limitation is required, and when noise exposure reduction is mandatory.

This is

typically

to 85 dBA.

The usual approach is to

control the

exposure time to the noise or to enclose the machine to reduce emitted

sound. Pump noise level is dependent on a number of operational factors, flow rate, pipe work design and

acoustic characteristics of the building, and so the values given are subject to a 3 dBA tolerance and cannot be

guaranteed.

1.6.1 Overall noise level

Tables below show dBA levels for two stage and three or more stage pumps, based on the best efficiency point

BEP at design RPM and required impeller diameter.

For specific gravities less than 1.0, use 1.0 specific gravity. For specific gravities above 1.0, use the actual

specific gravity.

When the required condition flow falls outside the range of 75% to 125% of BEP, a Part Load Correction (PLC)

must be added to the noise levels as follows:

PB3 User Instruction

Page 8 of 39

Percent of BEP at required Impeller Diameter

PLC DB

74 to 62 % or 126 to 136 % +1

61 to 50 % or 137 to 150 % +2

49 to 38 % +3

37 to 25 % +4

2 TRANSPORT AND STORAGE

2.1 Consignment receipt and unpacking

Immediately after receipt of the equipment it must be checked against the delivery/shipping documents for its

completeness and that there has been no damage in transportation.

Any shortage and or damage must be reported immediately to PUMPIRAN and received in writing within one

month of receipt of the equipment. Later claims cannot be accepted.

Check any crates, boxes and wrappings for any accessories or spare parts which may be packed separately with

the equipment or attached to side walls of the box or equipment.

Each product has a unique serial number. Checks that this number corresponds with that advised and always

quote this number in correspondence as well as when ordering spare parts or further accessories.

Brake Horse Power at BEP dBA

3 to 14 Stages

90 to 110 79

110 to 140 80

140 to 180 81

180 to 220 82

220 to 280 83

280 to 360 84

360 to 450 85

450 to 560 86

560 to 720 87

720 to 900 88

900 to 1125 89

1125 to 1400 90

1400 to 1800 91

1800 to 2250 92

2250 to 2800 93

2800 to 3600 94

3600 to 4500 95

4500 to 5700 96

5700 to 7200 97

7200 to 9000 98

9000 to 11000 99

11000 to 14000 100

Brake Horse Power at BEP

dBA

2 stages pump

250 to 350 87

350 to 500 88

500 to 700 89

700 to 940 90

940 to 1100 91

1100 to 1300 92

1300 to 1500 93

Above 1500, Pumpiran 94

PB3 User Instruction

Page 9 of 39

2.1.1 Receipt inspection

NOTE

The following information regarding receiving is only offered as a general guideline

to the customer. PUMPIRAN requires that all receiving be conducted in accordance

with specifications set forth in Chapter 3, Jobsite Receiving and Protection from API

Recommended Practices 686/PIP REIE 686, First Edition.

The pump and its associated equipment were carefully inspected at the factory prior to shipment to

ensure quality compliance. It is suggested that the pump be inspected upon arrival and that any

irregularities or damage be reported to the carrier immediately.

The protective covers on the pump nozzles should be in place and undamaged.

2.1.2 Unpacking

The pump should arrive already mounted on the base plate and it is therefore suggested that the unpacking of

the equipment should proceed per instruction as outlined in this manual.

In general, care is to be taken when removing crating, coverings, and strapping in order not to damage any

auxiliary equipment and/or the paint finish.

2.1.3 Paint/rust preventive

Internal parts of the pump and bearing housings are protected prior to shipment with a rust preventive such as

Dasco guard 2408M. This can be removed with petroleum solvents.

External non-machined surfaces are painted with one of applicable PUMPIRAN coating. Parts ordered

separately are protected with a rust preventive such as Dasco guard 2408M. This can be removed with

petroleum solvents.

2.2 Handling

Boxes, crates, pallets or cartons may be unloaded using forklift vehicles or slings dependent on their size and

construction.

2.3 Lifting

Caution

To avoid distortion, the pump unit should be lifted as shown.

2.3.1 Lifting equipment

NOTE

The following information regarding lifting is only offered as a general guideline.

PUMPIRAN requires that all lifting and rigging be performed in accordance with

specifications set forth in Chapter 2, Lifting and Rigging from API Recommended

Practices 686/PIP REIE 686, First Edition.

PB3 User Instruction

Page 10 of 39

WARNING

EQUIPMENT

CAPACITY

Make sure that any equipment used to lift the pump or any other of its components is

capable of supporting the total weight encountered. Make sure that all parts are properly

rigged before attempting to lift.

2.3.2 To lift unit

Caution

The complete unit with pump, driver and auxiliary equipment all mounted on the

base plate can NOT be lifted as a unit. Driver must be removed from base plate

before lifting. To lift unit sling base plate from all lifting eyes. Failure to do this may

result in permanent deformation of base plate.

Damage to base plate caused by mishandling or improper setting prior to grouting is

not covered by PUMPIRAN’s warranty

2.3.3 To lift driver

Refer to driver manufacturer’s instructions.

2.3.4 To lift pump

Install sling from overhead hoist and under bearing housing mounting brackets (cast portion of casing where

bearing housings attach).

Proper lifting practice for pump

WARNING

LIFTING PRACTICE

Do not lift entire pump from cast lifting lugs on upper half casings. These lugs are

for lifting upper half casing only.

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