Volute Casing Centrifugal Pumps Retain Series NI / Operating and Maintenance Instructions
Year: 2001 Language: english Author: ALLWEILER Genre: Operating and Maintenance Instructions Publisher: ALLWEILER Series: VM 466.0002 GB/06.01 – Ident–Nr. 550 113 Format: PDF Quality: OCR without errors Number of pages: 20 Description: Operating and Maintenance Instructions VM No.: 466.0002 GB / Edition: 06.01/ Ident No.: 550 113 Volute Casing Centrifugal Pumps Retain Series NI Operating data, dimensions and other additional information can be found in the order–specific part of the documentation. These Operating and Maintenance Instructions contain information from the pump manufacturer. They may need to be supplemented by instructions of the operator company for its personnel. These instructions do not take account of specific information relating to operation and maintenance of the process plant into which the pump is integrated. Such information can only be given by the persons responsible for construction and planning of the plant (plant manufacturer). Such specific instructions relating to operation and maintenance of the process plant into which the pump is integrated have priority over the instructions of the pump manufacturer. The plant manufacturer must on principle observe the limits of use! Refer to the operating instructions of the plant manufacturer!
Contents
1. General 2. Safety 3. Transportation and Intermediate Storage 4. Description 5. Installation/Mounting 6. Start–up/Shutdown 7. Maintenance/Repair 8. Operating Faults, Causes and Remedial Action 9. Associated Documentation Important note: This operating manual is to be supplemented by the order–related informations. NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 2
Pump designation / Safety / Transportation and Intermediate Storage
1 General 1.1 Pump designation The exact designation can be found in the order–specific documents (see data sheet). 1.2 Proper use Information on proper use of the pumps is provided in the technical data sheet. The pumped liquid must not contain any abrasive constituents nor corrode the pump materials. 1.3 Types of construction The pumps are supplied in various designs, differing mainly in the shaft seals and the materials. 1.4 Performance data The exact performance data can be taken from the order data sheet and/or acceptance test report. 1.5 Warranty Our warranty for shortcomings in the supply is laid down in our delivery conditions. No liability will be undertaken for damages caused by non–compliance with the operating instructions and service conditions. If at any later date the operating conditions change (e.g. different fluid conveyed, speed, viscosity, temperature or supply conditions), it must be checked by us from case to case and confirmed, if necessary, that the pump is suited for those purposes. Where no special agreements were made, pumps supplied by us may, during the warranty period, only be opened or varied by us or our authorized contract service workshops; otherwise our liability for any defects will cease. 1.6 Testing Prior to leaving our factory, all pumps are subjected to a leak test. Additional tests will only be performed on request. 1.7 Availability As a matter of principle, we recommend stocking replacement pumps and withdrawable units (hydraulic action system) where the supplied pumps are a decisive factor in maintaining a production or delivery process. In this way downtimes can be avoided, or reduced to a minimum. 1.8 Pressure limit The sum of inlet pressure and maximum delivery pressure must not be greater than the permissible internal pump pressure (see data sheet). NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 3 2 Safety These operating instructions contain basic safety instructions for installation, operation and maintenance. It is therefore essential that they are read by fitters and all specialist staff and customer personnel prior to installation and start–up. They must always be kept at hand at the place of installation. The special safety instructions contained in the other chapters must be observed in addition to the general safety instructions in this chapter. 2.1 Identification of safety instructions in the operating manual The safety instructions contained in these operating instructions which represent a danger to personnel if not complied with are specially marked by the general danger symbol: Warning symbol as per DIN 4844–W9 Warning of danger from electric voltage is indicated as follows: Warning symbol as per DIN 4844–W8. Instructions which are essential to avoid endangering the machine and its operation are marked by the word ATTENTION Instructions affixed directly to the machine such as Directional markers Signs for fluid connections must always be observed and maintained in fully legible condition at all times. 2.2 Personnel qualification and training The operating, maintenance, inspection and mounting personnel must be appropriately qualified for the duties assigned to them. The scope of their responsibilities, competency and supervisory duties must be closely controlled by the customer. If the personnel do not have the required knowledge, they must be trained and instructed. If required, this may be provided by the manufacturer/supplier on behalf of the customer. The customer must additionally ensure that personnel fully understand the content of the operating instructions. 2.3 Dangers in the event of non–compliance with safety instructions Failure to comply with the safety instructions may result in danger to persons, and place the environment and the machine at risk. Non–compliance with the safety instructions will lead to the loss of any claims for damages. Non–compliance may result in the following dangers: Failure of important functions of the plant Failure of specified methods for maintenance and servicing Danger to persons resulting from electrical, mechanical and chemical effects Danger to the environment resulting from leakage of hazardous substances 2.4 Responsible working practices The safety instructions contained in these operating instructions, current national accident prevention regulations, as well as internal working, operating and safety rules of the customer, must be observed. 2.5 Safety instructions for the user/operator Hot or cold machine parts representing a danger must be protected against accidental contact on site. Protection against accidental contact for moving parts (such as the coupling) must not be removed while the machine is in operation. When operating pump aggregates in a dust–laden environment (e.g. milling, chipboard manufacture, bakeries), the surfaces of the pumps and motors must be cleaned at regular intervals, depending on local conditions, in order to maintain the cooling effect and eliminate the possibility of spontaneous combustion. Please also see explosion protection regulations (ZH 1/10). Leakage (e.g. from the shaft seal) of hazardous substances being handled, such as explosive, toxic or hot materials, must be discharged in such a way that no danger to persons or the environment is created. Legal regulations must be observed. Dangers from electrical energy must be eliminated. For details in this regard, please refer to VDE and local power company regulations. NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 4 2.6 Safety instructions for maintenance, inspection and installation The operating company must ensure that all maintenance, inspection and installation tasks are performed by authorized and qualified specialist personnel who have thoroughly studied the operating instructions. Work on the machine is only to be carried out when the machine is at a standstill. The procedure for shutting down the machine described in the operating instructions must always be followed. Pumps or aggregates handling fluids which are detrimental to health must be decontaminated. All safety and protective devices must immediately be refitted and made operational on completion of the work. The instructions under Section 6.1, ”Preparation for start–up”, must be observed before restarting. 2.7 Unauthorized conversion and production of replacement parts Conversion or modification of the machines is only permissible after consultation with the manufacturer. Original replacement parts and accessories approved by the manufacturer are intrinsic to safe operation. If other parts are used the manufacturer cannot be held liable for the consequences. 2.8 Unacceptable modes of operation The operational safety of the machine supplied is only ensured when it is used in accordance with Section 1 of the operating instructions. The limit values given on the data sheet must not be exceeded under any circumstances. 3 Transportation and Intermediate Storage 3.1 Packaging Attention must be paid to the figurative markings on the packaging. The suction and pressure side and all auxiliary connections must always be closed during transportation and storage. The coverings must only be removed immediately before connecting the pipeline. 3.2 Transportation The pump or pump aggregate is to be safely transported to the place of installation, if required by means of lifting gear. The regulations for lifting loads in accordance with VBG 9a must be observed. Crane and sling equipment must be adequately dimensioned. Sling equipment must not be secured to the lifting eyes of the motor, except as additional protection against overturning in the event of nose–heaviness. Transportation to and at the installation site Make sure that the unit is transported safely and in a stable position. Overturning due to nose–heaviness must be prevented. Transport damage Check the pump for damage on receipt. Any damage detected must be notified immediately. NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 5 3.3 Preservation / Storage of centrifugal pumps 3.3.1 Preservation In the case of storage or prolonged standstill, the pumps must be protected against corrosion. In those cases, an outside and inside preservation is to be provided. The durability of the protection against corrosion, which is limited in time, depends on the composition of the preservative to be applied and the storage conditions. Under normal circumstances the pumps have no special preservative. At an additional charge we can, however, supply pumps and replacement parts ex factory with a preservative adequate to the planned storage period. 3.3.1.1 Outside preservation The outside preservative should be applied by painting or spraying with a spray gun. Points of preservation: All bright and unvarnished parts (e.g. shaft ends, couplings, flange facings, valve and manometer connections). 3.3.1.2 Inside preservation (Not required for pumps made of stainless materials.) Internal preservation is applied by painting, spraying using spray guns, filling/dipping and subsequent draining. Finally, the suction and outlet branches as well as all other supply and discharge branches must be sealed with dummy flanges or dummy plugs (plastic caps). Points of preservation: All bright parts inside the pump (e.g. pump casing inside, bearing bracket, shafts, impellers and diffusers). 3.3.1.3 Storage times Depending on the required storage period and the surroundings, we recommend the use of preservatives from Valvoline GmbH, Hamburg. Storage in a closed, dry and dust–free room Storage time up to 6 months up to 12 months over 12 months Internal preserrvation Tectyl 511 M Tectyl 511 M Tectyl 506 EH External preservation Tectyl 511 M Tectyl 511 M Tectyl 506 EH Storage in the open–air, central European climate Storage time up to 6 months up to 12 months over 12 months Internal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH External preservation Tectyl 542 Tectyl 506 EH Tectyl 506 EH Storage in the open–air, tropical climate, aggressive industrial air or proximity to the sea Storage time up to 6 months up to 12 months over 12 months Intermal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH External preservation Tectyl 506 EH Tectyl 506 EH Tectyl 506 EH Internal and external preservation must be renewed after 48 months at the latest. External preservation must be renewed after 18 months at the latest. Internal preservation must be renewed after 48 months at the latest. External preservation must be renewed after 12 months at the latest. Internal preservation must be renewed after 48 months at the latest. Note: The preservatives listed are to be regarded as a recommendation. Alternatively, technically equivalent products from other manufacturers can be used. When handling preservatives, the safety hints contained in the relevant DIN safety data sheets and those of the manufacturer must be complied with. 3.3.1.4 Depreservation Prior to setting the pump in motion, the inside preservation must be removed. Environmentally compatible disposal must be ensured. Preservatives can be removed with wax solvents, petroleum ether, diesel, petroleum or alkaline cleaners. However, the simplest method is to use a steam cleaner. Recommendation for Tectyl 506 EH: Allow petroleum ether to act for 10 minutes before any further action. Pumps that are used in the food or drinking water sector must be dismantled and thoroughly cleaned prior to depreservation. A suitable solvent that is compatible with the liquid to be pumped (drinking water/food) can be used as the cleaning agent, e.g. Spiritus, Ritzol 155 or suds with a high alkaline content. Steam cleaning is ideal. After a prolonged storage period (more than 6 months), all elastomers (O–rings, shaft seals) must be checked for elasticity of shape. Embrittled elastomers must be replaced. EP rubber elastomers (EPDM) must be replaced on principle. 3.3.2 Storage During storage of the pump, the suction and outlet branches and all other supply and discharge branches must always be closed with dummy flanges or dummy plugs. Storage should be in a dry, dust–free room. During storage, the pump should be cranked at least once a month. During this process, parts such as the shaft and bearings should change their position. 3.3.3 Monitoring of preservation The preservation must be checked at regular intervals. The preserved areas must be inspected every 6 months and re–treated, if necessary. We cannot accept any liability for defects that arise due to incorrect preservation treatment. NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 6 4 Description / Principle design of the pump The pictorial presentation may not correspond with the pump supplied. The actual design will be stated in the specific order documents. Volute casing Impeller Motor stool Plug–in shaft Contact protection to EN 809 Shaft seal space Earthing connection to EN 809 must be attached by the customer Motor with locating bearing at the driving side NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 7 5 Installation/Mounting 5.1 Installation For installation methods and locations, please see installation drawing. Other methods of installation are not permissible without prior consultation with the manufacturer. 5.1.1 Place of installation Temperature: min. –20 C max. +40 C relative air humidity: permanent max. 85 % temporary max. 100 % Installation height: max. 1000 m above NN For data differing from this, please consult the manufacturer. Intensive vibrations in the vicinity of the pump unit can lead to bearing damage and must therefore be avoided. Pumpes used for the delivery of water must be installed so that they are protected against freezing. 5.1.2 Protective devices In order to prevent injuries due to burns, at pumping liquid temperatures higher than 60C protective devices in accordance with EN 809 must be provided on site. Heat insulation Only the volute housing may be insulated with heat insulating material. In order to enable optimum heat dissipation no other pump components may be insulated. 5.1.3 Fixing the pump aggregate The pump is directly mounted into the pipeline. The pipelines must be constructed in such a way that they can take the weight of the pump unit and all operating forces that occur. The prescribed tightening torque (Section 7.2.3) must be observed. Precise details of the fixing are provided in the installation drawing. 5.2 Assembly of pump and drive motor If the aggregate is only assembled at the place of use, the coupling is assembled as follows: 1. Remove the distance piece for shaft screwed to the motor stool (341.01) for securing the pump shaft (220...). For these purposes, loosen hexagon screws (901.10). Note: The hexagon screws (901.10) serve for fixing the motor. 2. Screw out hexagon screws (901.07), remove washers (554.07), and remove one half of the guard plate (686.01) from the motor stool (341.01). 3. Loosen socket–head cap screw (914.06) in the pump shaft (220...), and screw out completely. Note: The hexagon socket screw key required for loosening the socket–head cap screw (914.06) is inserted in one of the two cast–in recesses in the motor stool. 4. Mount flange motor and fix it. 5. Mount the contact protection. According to accident prevention regulations, the pump must only be operated with a protection against accidental contact. 5.3 Space required for maintenance and repair The pump must be accessible from all sides in order to be able to carry out necessary visual inspections. Adequate space must be provided for maintenance and repair work, in particular for removal of the drive motor or of the complete pump aggregate. It must also be ensured that all pipelines can be attached and removed without hindrance. 5.4 Laying the pipelines 5.4.1 Nominal widths The nominal diameters of the pipelines need not necessarily correspond to those of the inlet and outlet branch, however, they must not be smaller. Different nominal diameters of suction branches and suction pipelines are to be compensated by centric transition pieces. Formation of air bags is to be avoided. Figure DN 1 Recommendation for straight pipeline length before and after the pump min. 5xDNs min. 5xDNd In these areas, pipe fittings such as gate valves, bends, compensators etc. should be avoided wherever possible. Shorter pipelines on the suction side are possible, but may lead to a deterioration of the hydraulic performance data. Shorter pipelines on the discharge side are possible, but may lead to increased noise development. Compensators must not generate any unacceptable additional forces on the pump connection branches. Special care is needed in cases where compensators are used, whose pressurised diameter is greater than the nominal width of the pump connection branches. NI VM 466.0002 GB/06.01 – Ident–Nr. 550 113 8 5.4.2 Changes in cross–section and direction Sudden changes in cross–section and direction, as well as bends with a bend radius less than 1.5 times the interior pipe width, must be avoided. 5.4.3 Supports and flange connections All pipelines must be connected to the pump stress–free in accordance with VDMA standard sheet 24277. The permissible pipeline forces must not be exceeded in any operating status. We therefore recommend on principle that a calculation of the pipeline forces is performed, which takes into consideration all operating status (e.g. cold/warm, empty/full, depressurised/pressurised, etc.). Pipeline supports must always be free sliding and must not rust in (check regularly). How to assess a pipeline connection To conduct an assessment, the pipeline must be depressurised, completely drained and cooled. The pumping liquid must be disposed of with respect for the environment. Disconnect the pipeline from the pump at the connecting flanges. After disconnecting the connecting flanges, the pipeline must be freely movable in all directions in the area of expected expansion. Note: up to Ø 150 mm by hand from Ø 150 mm with small lever The flanges must lie plane–parallel. 5.4.4 Cleaning pipelines prior to attachment Prior to assembly, all pipeline parts and valves must be thoroughly cleaned. No impurities must reach the pump from the pipeline system (e.g. welding beads, residues from preservatives, etc.). Flange gaskets must not protrude inwards. Blanking flanges, plugs, protective film and/or protective paint on flanges and seals must be removed completely. Filters on suction side must be cleaned regularly. We recommend monitoring with differential manometer and/or contact manometer. 5.4.5 NPSH observation The NPSH conditions of the system must be adapted to the respective pump requirement (NPSHreq.). An essential condition is fulfilled if the system NPSH value (NPSHavail.) is at least 0,5 m above the pump NPSH value (NPSHreq.). The NPSHreq. can be taken from the characteristic curves of the relevant pumps. The applicable NPSH values in the characteristic curves are for water with 20C. For other media and/or temperatures, the NPSH value may deviate from the characteristic curves. Uncertainties in the determination of NPSH conditions, particularly for media other than water and/or other temperatures, must be compensated for by increased safety factors (please consult the manufacturer). 5.4.6 Suction and inlet pipeline In order to avoid the formation of air bags, the suction and inlet pipeline must be laid rising to the pump. 5.4.6.1 Foot valve and suction basket (suction mode) For suction operation, the suction pipeline must be equipped with a foot valve preventing the pump and suction pipeline from running empty while at rest. The suction basket must be attached so that neither dirt from the sump nor air from the fluid level can enter. 5.4.6.2 Stop valve (inlet mode) A stop valve is to be installed in the inlet pipeline. It must be fully open during operation (see figure DN 1). 5.4.7 Pressure pipeline 5.4.7.1 Stop valve in the pressure pipeline A stop valve should be installed in the pressure pipeline. 5.4.7.2 Non–return valve in the pressure pipeline The pump must not run backwards. It is recommended that a non–return valve is fitted between the pressure branch and the stop valve. 5.4.7.3 Bleeding In the pressure pipeline, bleeding facilities should be provided at the highest point and in front of the non–return valve. 5.4.8 Auxiliary connections The positions of the auxiliary connections on the pump are shown in the installation drawing. All auxiliary pipelines must be connected in accordance with the installation drawing, stress–free and sealed. 5.5 Safety and control devices 5.5.1 Manometers We recommend to provide suitable pressure gauges in the inlet and pressure pipelines, and in the pressurized auxiliary pipelines. 5.5.2 Safety devices in the inlet, delivery and auxiliary pipelines Safety devices in the form of stop valves must be installed in the pipelines, if not already provided, to allow the pipelines to be shut off and disconnected during maintenance and repair work. 5.6 Electrical connections The power supply cables of the drive motor must be connected by a trained electrician, according to the motor manufacturer’s circuit diagram. The valid VDE regulations, the regulations of the local electricity board and the operating manual for the motor must be complied with. Danger due to electrical power must be excluded and an EMERGENCY STOP switch in accordance with EN 809 must be provided. The pump must not run dry, not even for checking the sense of rotation. Refer 6.1... Control of drive motor sense of rotation
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Volute Casing Centrifugal Pumps Retain Series NI / Operating and Maintenance Instructions
Language: english
Author: ALLWEILER
Genre: Operating and Maintenance Instructions
Publisher: ALLWEILER
Series: VM 466.0002 GB/06.01 – Ident–Nr. 550 113
Format: PDF
Quality: OCR without errors
Number of pages: 20
Description: Operating and Maintenance Instructions VM No.: 466.0002 GB / Edition: 06.01/ Ident No.: 550 113
Volute Casing Centrifugal Pumps Retain Series NI
Operating data, dimensions and other additional information can be found in the order–specific part of the
documentation.
These Operating and Maintenance Instructions contain information from the pump manufacturer. They may need
to be supplemented by instructions of the operator company for its personnel.
These instructions do not take account of specific information relating to operation and maintenance of the process
plant into which the pump is integrated.
Such information can only be given by the persons responsible for construction and planning of the plant (plant
manufacturer).
Such specific instructions relating to operation and maintenance of the process plant into which the pump is
integrated have priority over the instructions of the pump manufacturer.
The plant manufacturer must on principle observe the limits of use! Refer to the operating instructions of the plant manufacturer!
Contents
1. General2. Safety
3. Transportation and Intermediate
Storage
4. Description
5. Installation/Mounting
6. Start–up/Shutdown
7. Maintenance/Repair
8. Operating Faults, Causes and
Remedial Action
9. Associated Documentation
Important note:
This operating manual is to be supplemented
by the order–related informations.
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 2
Pump designation / Safety / Transportation and Intermediate Storage
1 General1.1 Pump designation
The exact designation can be found in the order–specific
documents (see data sheet).
1.2 Proper use
Information on proper use of the pumps is provided in
the technical data sheet.
The pumped liquid must not contain any abrasive constituents
nor corrode the pump materials.
1.3 Types of construction
The pumps are supplied in various designs, differing
mainly in the shaft seals and the materials.
1.4 Performance data
The exact performance data can be taken from the order
data sheet and/or acceptance test report.
1.5 Warranty
Our warranty for shortcomings in the supply is laid
down in our delivery conditions. No liability will be undertaken
for damages caused by non–compliance with
the operating instructions and service conditions.
If at any later date the operating conditions change (e.g.
different fluid conveyed, speed, viscosity, temperature
or supply conditions), it must be checked by us from
case to case and confirmed, if necessary, that the pump
is suited for those purposes. Where no special agreements
were made, pumps supplied by us may, during
the warranty period, only be opened or varied by us or
our authorized contract service workshops; otherwise
our liability for any defects will cease.
1.6 Testing
Prior to leaving our factory, all pumps are subjected to
a leak test. Additional tests will only be performed on request.
1.7 Availability
As a matter of principle, we recommend stocking
replacement pumps and withdrawable units (hydraulic
action system) where the supplied pumps are a
decisive factor in maintaining a production or delivery
process. In this way downtimes can be avoided, or
reduced to a minimum.
1.8 Pressure limit
The sum of inlet pressure and maximum delivery pressure
must not be greater than the permissible internal
pump pressure (see data sheet).
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 3
2 Safety
These operating instructions contain basic safety
instructions for installation, operation and
maintenance. It is therefore essential that they are read
by fitters and all specialist staff and customer personnel
prior to installation and start–up. They must always be
kept at hand at the place of installation.
The special safety instructions contained in the other
chapters must be observed in addition to the general
safety instructions in this chapter.
2.1 Identification of safety instructions in the
operating manual
The safety instructions contained in these operating
instructions which represent a danger to personnel if
not complied with are specially marked by the general
danger symbol:
Warning symbol
as per DIN 4844–W9
Warning of danger from electric voltage is indicated as
follows:
Warning symbol
as per DIN 4844–W8.
Instructions which are essential to avoid endangering
the machine and its operation are marked by the word
ATTENTION
Instructions affixed directly to the machine such as
Directional markers
Signs for fluid connections
must always be observed and maintained in fully
legible condition at all times.
2.2 Personnel qualification and training
The operating, maintenance, inspection and mounting
personnel must be appropriately qualified for the duties
assigned to them. The scope of their responsibilities,
competency and supervisory duties must be closely
controlled by the customer. If the personnel do not have
the required knowledge, they must be trained and
instructed. If required, this may be provided by the
manufacturer/supplier on behalf of the customer. The
customer must additionally ensure that personnel fully
understand the content of the operating instructions.
2.3 Dangers in the event of non–compliance with
safety instructions
Failure to comply with the safety instructions may result
in danger to persons, and place the environment and
the machine at risk. Non–compliance with the safety
instructions will lead to the loss of any claims for
damages.
Non–compliance may result in the following dangers:
Failure of important functions of the plant
Failure of specified methods for maintenance and
servicing
Danger to persons resulting from electrical,
mechanical and chemical effects
Danger to the environment resulting from leakage of
hazardous substances
2.4 Responsible working practices
The safety instructions contained in these operating
instructions, current national accident prevention
regulations, as well as internal working, operating and
safety rules of the customer, must be observed.
2.5 Safety instructions for the user/operator
Hot or cold machine parts representing a danger
must be protected against accidental contact on
site.
Protection against accidental contact for moving
parts (such as the coupling) must not be removed
while the machine is in operation.
When operating pump aggregates in a dust–laden
environment (e.g. milling, chipboard manufacture,
bakeries), the surfaces of the pumps and motors
must be cleaned at regular intervals, depending on
local conditions, in order to maintain the cooling
effect and eliminate the possibility of spontaneous
combustion. Please also see explosion protection
regulations (ZH 1/10).
Leakage (e.g. from the shaft seal) of hazardous
substances being handled, such as explosive, toxic
or hot materials, must be discharged in such a way
that no danger to persons or the environment is
created. Legal regulations must be observed.
Dangers from electrical energy must be eliminated.
For details in this regard, please refer to VDE and
local power company regulations.
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 4
2.6 Safety instructions for maintenance, inspection
and installation
The operating company must ensure that all
maintenance, inspection and installation tasks are
performed by authorized and qualified specialist
personnel who have thoroughly studied the operating
instructions.
Work on the machine is only to be carried out when the
machine is at a standstill. The procedure for shutting
down the machine described in the operating
instructions must always be followed.
Pumps or aggregates handling fluids which are
detrimental to health must be decontaminated. All
safety and protective devices must immediately be
refitted and made operational on completion of the
work.
The instructions under Section 6.1, ”Preparation for
start–up”, must be observed before restarting.
2.7 Unauthorized conversion and production of
replacement parts
Conversion or modification of the machines is only
permissible after consultation with the manufacturer.
Original replacement parts and accessories approved
by the manufacturer are intrinsic to safe operation. If
other parts are used the manufacturer cannot be held
liable for the consequences.
2.8 Unacceptable modes of operation
The operational safety of the machine supplied is only
ensured when it is used in accordance with Section 1 of
the operating instructions. The limit values given on the
data sheet must not be exceeded under any
circumstances.
3 Transportation and Intermediate Storage
3.1 Packaging
Attention must be paid to the figurative markings on the
packaging.
The suction and pressure side and all auxiliary connections
must always be closed during transportation and
storage.
The coverings must only be removed immediately
before connecting the pipeline.
3.2 Transportation
The pump or pump aggregate is to be safely transported
to the place of installation, if required by means
of lifting gear.
The regulations for lifting loads in accordance with
VBG 9a must be observed. Crane and sling equipment
must be adequately dimensioned. Sling
equipment must not be secured to the lifting eyes
of the motor, except as additional protection
against overturning in the event of nose–heaviness.
Transportation to and at the installation site
Make sure that the unit is transported safely and in a
stable position. Overturning due to nose–heaviness
must be prevented.
Transport damage
Check the pump for damage on receipt.
Any damage detected must be notified immediately.
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 5
3.3 Preservation / Storage of centrifugal pumps
3.3.1 Preservation
In the case of storage or prolonged standstill, the
pumps must be protected against corrosion. In those
cases, an outside and inside preservation is to be provided.
The durability of the protection against corrosion,
which is limited in time, depends on the composition
of the preservative to be applied and the storage
conditions.
Under normal circumstances the pumps
have no special preservative.
At an additional charge we can, however, supply
pumps and replacement parts ex factory with a preservative
adequate to the planned storage period.
3.3.1.1 Outside preservation
The outside preservative should be applied by painting
or spraying with a spray gun.
Points of preservation:
All bright and unvarnished parts (e.g. shaft ends, couplings,
flange facings, valve and manometer connections).
3.3.1.2 Inside preservation
(Not required for pumps made of stainless materials.)
Internal preservation is applied by painting, spraying
using spray guns, filling/dipping and subsequent draining.
Finally, the suction and outlet branches as well as
all other supply and discharge branches must be
sealed with dummy flanges or dummy plugs (plastic
caps).
Points of preservation:
All bright parts inside the pump (e.g. pump casing inside,
bearing bracket, shafts, impellers and diffusers).
3.3.1.3 Storage times
Depending on the required storage period and the surroundings,
we recommend the use of preservatives
from Valvoline GmbH, Hamburg.
Storage in a closed, dry and dust–free room
Storage time up to 6 months up to 12 months over 12 months
Internal preserrvation Tectyl 511 M Tectyl 511 M Tectyl 506 EH
External preservation Tectyl 511 M Tectyl 511 M Tectyl 506 EH
Storage in the open–air, central European climate
Storage time up to 6 months up to 12 months over 12 months
Internal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 542 Tectyl 506 EH Tectyl 506 EH
Storage in the open–air, tropical climate, aggressive industrial air or
proximity to the sea
Storage time up to 6 months up to 12 months over 12 months
Intermal preservation Tectyl 542 Tectyl 542 Tectyl 506 EH
External preservation Tectyl 506 EH Tectyl 506 EH Tectyl 506 EH
Internal and external preservation must be renewed after 48 months at the latest.
External preservation must be renewed after 18 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
External preservation must be renewed after 12 months at the latest.
Internal preservation must be renewed after 48 months at the latest.
Note: The preservatives listed are to be regarded as a
recommendation. Alternatively, technically equivalent
products from other manufacturers can be used.
When handling preservatives, the safety hints contained
in the relevant DIN safety data sheets and those
of the manufacturer must be complied with.
3.3.1.4 Depreservation
Prior to setting the pump in motion, the inside preservation
must be removed.
Environmentally compatible disposal must be ensured.
Preservatives can be removed with wax solvents, petroleum
ether, diesel, petroleum or alkaline cleaners.
However, the simplest method is to use a steam cleaner.
Recommendation for Tectyl 506 EH: Allow petroleum
ether to act for 10 minutes before any further action.
Pumps that are used in the food or drinking water sector
must be dismantled and thoroughly cleaned prior to depreservation.
A suitable solvent that is compatible with the liquid to be
pumped (drinking water/food) can be used as the
cleaning agent, e.g. Spiritus, Ritzol 155 or suds with a
high alkaline content. Steam cleaning is ideal.
After a prolonged storage period (more
than 6 months), all elastomers (O–rings,
shaft seals) must be checked for elasticity of shape.
Embrittled elastomers must be replaced. EP rubber
elastomers (EPDM) must be replaced on principle.
3.3.2 Storage
During storage of the pump, the suction and outlet
branches and all other supply and discharge branches
must always be closed with dummy flanges or dummy
plugs.
Storage should be in a dry, dust–free room. During storage,
the pump should be cranked at least once a
month. During this process, parts such as the shaft and
bearings should change their position.
3.3.3 Monitoring of preservation
The preservation must be checked at regular intervals.
The preserved areas must be inspected every 6
months and re–treated, if necessary.
We cannot accept any liability for defects
that arise due to incorrect preservation
treatment.
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 6
4 Description / Principle design of the pump
The pictorial presentation may not correspond with the pump supplied.
The actual design will be stated in the specific order documents.
Volute casing Impeller
Motor stool
Plug–in shaft
Contact protection
to EN 809
Shaft seal space
Earthing connection to EN 809
must be attached by the customer
Motor with locating
bearing at the driving
side
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 7
5 Installation/Mounting
5.1 Installation
For installation methods and locations, please see installation
drawing.
Other methods of installation are not permissible
without prior consultation with the manufacturer.
5.1.1 Place of installation
Temperature: min. –20 C
max. +40 C
relative air humidity:
permanent max. 85 %
temporary max. 100 %
Installation height: max. 1000 m above NN
For data differing from this, please consult the manufacturer.
Intensive vibrations in the vicinity of the
pump unit can lead to bearing damage and
must therefore be avoided.
Pumpes used for the delivery of water
must be installed so that they are protected
against freezing.
5.1.2 Protective devices
In order to prevent injuries due to burns, at pumping
liquid temperatures higher than 60C protective devices
in accordance with EN 809 must be provided on
site.
Heat insulation
Only the volute housing may be insulated
with heat insulating material. In order to
enable optimum heat dissipation no other pump components
may be insulated.
5.1.3 Fixing the pump aggregate
The pump is directly mounted into the pipeline.
The pipelines must be constructed in such
a way that they can take the weight of the
pump unit and all operating forces that occur.
The prescribed tightening torque (Section
7.2.3) must be observed.
Precise details of the fixing are provided in the installation
drawing.
5.2 Assembly of pump and drive motor
If the aggregate is only assembled at the place of use,
the coupling is assembled as follows:
1. Remove the distance piece for shaft screwed to the
motor stool (341.01) for securing the pump shaft
(220...). For these purposes, loosen hexagon
screws (901.10).
Note: The hexagon screws (901.10) serve for fixing
the motor.
2. Screw out hexagon screws (901.07), remove
washers (554.07), and remove one half of the guard
plate (686.01) from the motor stool (341.01).
3. Loosen socket–head cap screw (914.06) in the
pump shaft (220...), and screw out completely.
Note: The hexagon socket screw key required for
loosening the socket–head cap screw (914.06) is inserted
in one of the two cast–in recesses in the
motor stool.
4. Mount flange motor and fix it.
5. Mount the contact protection.
According to accident prevention regulations, the
pump must only be operated with a protection
against accidental contact.
5.3 Space required for maintenance and repair
The pump must be accessible from all
sides in order to be able to carry out
necessary visual inspections.
Adequate space must be provided for maintenance
and repair work, in particular for removal of the drive
motor or of the complete pump aggregate. It must also
be ensured that all pipelines can be attached and
removed without hindrance.
5.4 Laying the pipelines
5.4.1 Nominal widths
The nominal diameters of the pipelines need not
necessarily correspond to those of the inlet and outlet
branch, however, they must not be smaller. Different
nominal diameters of suction branches and suction
pipelines are to be compensated by centric transition
pieces. Formation of air bags is to be avoided.
Figure DN 1
Recommendation for straight pipeline length
before and after the pump
min. 5xDNs min. 5xDNd
In these areas, pipe fittings such as gate valves, bends,
compensators etc. should be avoided wherever possible.
Shorter pipelines on the suction side are
possible, but may lead to a deterioration of
the hydraulic performance data. Shorter pipelines on
the discharge side are possible, but may lead to increased
noise development.
Compensators must not generate any unacceptable
additional forces on the pump
connection branches. Special care is needed in cases
where compensators are used, whose pressurised diameter
is greater than the nominal width of the pump
connection branches.
NI
VM 466.0002 GB/06.01 – Ident–Nr. 550 113 8
5.4.2 Changes in cross–section and direction
Sudden changes in cross–section and direction, as
well as bends with a bend radius less than 1.5 times the
interior pipe width, must be avoided.
5.4.3 Supports and flange connections
All pipelines must be connected to the
pump stress–free in accordance with
VDMA standard sheet 24277.
The permissible pipeline forces must not
be exceeded in any operating status.
We therefore recommend on principle that a calculation
of the pipeline forces is performed, which takes into
consideration all operating status (e.g. cold/warm,
empty/full, depressurised/pressurised, etc.).
Pipeline supports must always be free sliding and must
not rust in (check regularly).
How to assess a pipeline connection
To conduct an assessment, the pipeline must be depressurised,
completely drained and cooled. The
pumping liquid must be disposed of with respect for the
environment.
Disconnect the pipeline from the pump at the connecting
flanges.
After disconnecting the connecting flanges, the
pipeline must be freely movable in all directions in
the area of expected expansion.
Note: up to Ø 150 mm by hand
from Ø 150 mm with small lever
The flanges must lie plane–parallel.
5.4.4 Cleaning pipelines prior to attachment
Prior to assembly, all pipeline parts and valves must be
thoroughly cleaned.
No impurities must reach the pump from
the pipeline system (e.g. welding beads,
residues from preservatives, etc.).
Flange gaskets must not protrude inwards. Blanking
flanges, plugs, protective film and/or protective paint on
flanges and seals must be removed completely.
Filters on suction side must be cleaned
regularly. We recommend monitoring with
differential manometer and/or contact manometer.
5.4.5 NPSH observation
The NPSH conditions of the system must be adapted to
the respective pump requirement (NPSHreq.).
An essential condition is fulfilled if the system NPSH value
(NPSHavail.) is at least 0,5 m above the pump
NPSH value (NPSHreq.). The NPSHreq. can be taken
from the characteristic curves of the relevant pumps.
The applicable NPSH values in the characteristic
curves are for water with 20C.
For other media and/or temperatures, the NPSH value
may deviate from the characteristic curves.
Uncertainties in the determination of
NPSH conditions, particularly for media
other than water and/or other temperatures, must be
compensated for by increased safety factors (please
consult the manufacturer).
5.4.6 Suction and inlet pipeline
In order to avoid the formation of air bags, the suction
and inlet pipeline must be laid rising to the pump.
5.4.6.1 Foot valve and suction basket (suction mode)
For suction operation, the suction pipeline must be
equipped with a foot valve preventing the pump and
suction pipeline from running empty while at rest.
The suction basket must be attached so that neither dirt
from the sump nor air from the fluid level can enter.
5.4.6.2 Stop valve (inlet mode)
A stop valve is to be installed in the inlet pipeline. It must
be fully open during operation (see figure DN 1).
5.4.7 Pressure pipeline
5.4.7.1 Stop valve in the pressure pipeline
A stop valve should be installed in the pressure pipeline.
5.4.7.2 Non–return valve in the pressure pipeline
The pump must not run backwards. It is recommended
that a non–return valve is fitted between the pressure
branch and the stop valve.
5.4.7.3 Bleeding
In the pressure pipeline, bleeding facilities should be
provided at the highest point and in front of the non–return
valve.
5.4.8 Auxiliary connections
The positions of the auxiliary connections on the pump
are shown in the installation drawing. All auxiliary
pipelines must be connected in accordance with the
installation drawing, stress–free and sealed.
5.5 Safety and control devices
5.5.1 Manometers
We recommend to provide suitable pressure gauges in
the inlet and pressure pipelines, and in the pressurized
auxiliary pipelines.
5.5.2 Safety devices in the inlet, delivery and auxiliary
pipelines
Safety devices in the form of stop valves must be
installed in the pipelines, if not already provided, to
allow the pipelines to be shut off and disconnected
during maintenance and repair work.
5.6 Electrical connections
The power supply cables of the drive motor must be
connected by a trained electrician, according to the
motor manufacturer’s circuit diagram. The valid VDE
regulations, the regulations of the local electricity board
and the operating manual for the motor must be
complied with.
Danger due to electrical power must be excluded and
an EMERGENCY STOP switch in accordance with EN
809 must be provided.
The pump must not run dry, not even for
checking the sense of rotation.
Refer 6.1... Control of drive motor sense of rotation
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