All Booster Pumps

RUHRPUMPEN

RUHRPUMPEN GMBH Witten - Annen

Operation and Maintenance P-10-11 A/B/C

Manufacturer's Address:

Serial Number

182508 A/B/C

Customer

HPCL

Creation Date

8.3.2010

Revision

0

Stockumer Str. 28 D-58453 Witten Telephone: +49 (0)23 02 / 661-03 Telefax: +49 (0)2302 / 661 199

Contents 12-PC-303-B

Contents

1

Foreword

2

General Information

3

4

5

6

2.1

Laws, Regulations and Standards

2.2

Marking of Special Instructions and Information

Fundamental Safety Instructions 3.1

Preliminary Remarks

3.2

Personnel Qualification and Training

3.3

Dangers If the Safety Instructions Are Ignored

3.4

Safety Conscious Working

3.5

Safety Instructions for Installation and Maintenance Work

3.6

Unauthorized Modification and Fabrication of Spare Parts

3.7

Prohibited Modes of Operation

Startup/Shutdown 4.1

Startup

4.2

Shutdown

4.3

Measures for Standstill

Maintenance 5.1

Notes on Maintenance

5.2

Maintenance Schedule

5.3

Lubricant Change

Troubleshooting 6.1

7

Causes and Corrective Measures

Manufacturer's Declaration

Foreword 12-PC-303-B

1

Foreword This manual contains fundamental information and instructions that must be followed during operation and maintenance. The fitter and responsible technical staff/operator must therefore read this manual before operation. It must be kept readily at hand at the place of use of the machine/plant at all times. If problems arise, please contact the customer service department of Ruhrpumpen GmbH. During the warranty period only employees of Ruhrpumpen GmbH may open the pump. Please state the following with all inquiries:  the order number and  the type designation of the unit. This information can be found on the pump's rating plate. For spare part orders please also state: 

the designations of the individual parts required and  their part numbers and identnumbers. Only spare parts and auxiliary materials approved by the manufacturer/supplier of the machine may be used for repairs and preventative maintenance (e.g. replacement of wearing parts). Approved spare parts and auxiliary materials are all spare parts and auxiliary materials named in the manual and attached supplier documentation. Contact the manufacturer/supplier if you are unsure about the use of spare parts and other materials from other manufacturers. If necessary, get the manufacturer of the spare parts/materials to certify the safety and compatibility of use of its products in writing. Ruhrpumpen GmbH accepts no liability and grants no warranty if spare parts or auxiliary materials not named in this manual or the attached documentation are used. .

General Information

2

General Information 2.1 Laws, Regulations and Standards The machine was built in compliance with the laws, regulations and technical rules of the Federal Republic of Germany. Conformity with the directives and harmonized standards of the European Union (EU) is guaranteed (see declaration of conformity/manufacturer's declaration). If the pump is installed and operated outside the above-mentioned territory, all regulations of the country in which it is used must also be followed. If further documents or additions to this manual then become necessary, this manual must be revised or supplemented with the necessary replacements or additional information. 2.2 Marking of Special Instructions and Information Important information and instructions (e.g. warnings of hazards or information on operating safety) are specially highlighted in this documentation as follows. Safety instructions that could lead to hazards for personnel if ignored are marked:

 with the general danger sign for "warning of life-threatening injuries"

(safety according to DIN 4844 - W 9)

 with the danger sign for "warning of electric voltage" (safety according

to DIN 4844 - W 8)

 with the danger sign "Attention" to warn of dangers for the machine

and its functions. If the pump unit is to be used in a potentially explosive environment, it must be suitable for such use. Applicable instructions in this regard must be observed.

Instructions attached directly to the machine, e.g.  direction of rotation arrow  markings for fluid connections

must be followed and kept in a completely legible state at all times.

Fundamental Safety Instructions 12-PC-303-B

3

Fundamental Safety Instructions 3.1 Preliminary Remarks The machine was designed and built in accordance with the state of the art and generally accepted technical safety rules! Dangers can nevertheless arise during operation  that threaten the health and life of the user/operator,  that lead to damage to the machine or plant,  that lead to damage to the environment or other assets. The machine may therefore only be used when it is in sound technical condition. It may only be used for the purpose intended and the user/operator must remain alert for safety issues and dangers during operation. This includes full compliance with the complete documentation!

3.2 Personnel Qualification and Training The personnel used for installation must be appropriately qualified for this work. The operator must define exactly the sphere of responsibility, competence and supervision of the personnel. If the personnel are not suitably qualified, they must be given appropriate training and instructions. This can be given, if necessary, by the manufacturer/supplier on behalf of the operator. The operator must further ensure that the contents of the manual are fully understood by the personnel.

3.3 Dangers If the Safety Instructions Are Ignored Ignoring the safety instructions may lead to hazards to persons, the environment and machine. Non-observance of the safety instructions may invalidate all and any claims for compensation. Non-observance may, for example, result in the following hazards:  failure of important functions of the machine/plant.  failure of prescribed methods for maintenance and repair.  hazards to persons from electrical, mechanical, thermal and chemical influences.  hazards to the environment from leaks of harmful substances.

Fundamental Safety Instructions 3.4 Safety Conscious Working Observe the safety instructions contained in the manual as well as existing national accident prevention regulations and any internal working, operating and safety regulations prescribed by the operator. 3.5 Safety Instructions for Installation and Maintenance Work All work on the plant may strictly only be carried out when the plant is at a standstill and the pressure and voltage supply have been disconnected. The procedure described in the manual to shut down the plant must be followed. All safety devices and safeguards must be remounted and rendered operative again immediately after the work has been completed. Before the pump is started again, the points listed for initial startup must be observed. 3.6 Unauthorized Modification and Fabrication of Spare Parts Modifications and changes to the plant are only permitted after consultation with the manufacturer. Original spare parts and accessories authorized by the manufacturer serve safety. The use of other parts can cancel liability for the resultant consequences.

3.7 Prohibited Modes of Operation The operational safety of the plant is only guaranteed if it is used as intended. The limit values specified in the datasheet may not be exceeded under any circumstances. Deviations from the operating parameters compromise the explosion protection of the pump unit.

Startup / Shutdown

4

Startup/Shutdown 4.1

Startup The plant should be monitored continuously during the first hours of operation. In this way it is possible to identify irregularities immediately and to take appropriate steps to eliminate them (troubleshooting help). The safeguards must be mounted and fastened before every startup of the plant.

For non-insulated hot surfaces of pumps, protective equipment must be used while working in the pump area. The pumps are to be secured by shut off devices with warning signs against unintended touching.

To avert dangers from malfunctions, the pump units must be equipped with emergency stop systems.

When operating electric drives, controllers and their cable routing, the safety instructions of the manufacturers of these components must be followed. In the first phase of operation all potentially hot surfaces (e.g. bearings and dynamic seals) must be observed with increased attention.

4.1.1 Preparing the Plant for Startup The plant has been installed and connected properly and correctly. 

If applicable, remove the corrosion protection for internal parts. Caution Decouple the pump before switching on the drive to check its direction of rotation.



Is the direction of rotation of the driving motor okay?

Startup / Shutdown 

Fill the bearing with lubricant. If you need cooling liquid for your operating conditions, open the valves for the cooling water line. Check that the coupling guard is screwed on firmly.

 

4.1.2 Venting Venting a pump means removing air, gas or steam from the pipes and pump casing. If the casing is not filled completely with liquid, the pump is unable to attain its performance specifications and damage can occur in the rotor gap areas due to contact. A pump can be vented in various ways. Two typical methods are described below. The explosion protection of the unit is only guaranteed if it is filled and vented correctly. A Positive Suction Head (Pressure): With a positive suction head in the pump, vent as follows:  Open all suction valves so that the medium can flow into the suction lines

and pump casing.  Open all available valves at the highest point of the pump and/or pipe to allow the air enclosed there to escape. Note: Some types of pump are self-venting and therefore do not have any vent valves.  When a steady flow (no air bubbles) of liquid appears, the pump has been vented. The valve can then be closed and the pump started. B Negative Suction Head (Vacuum): The pump must be evacuated before operation so that it is filled completely with liquid. Proceed as follows:  Open the suction valve.  Start evacuation of the pump and suction line by sucking with a vacuum unit (vacuum pump, fluid entrainment pump, etc.).  When only liquid is being pumped, the pump can be started.  The vacuum unit should, however, remain in operation until the pump has reached its rated shaft speed. 4.1.3 Start Before switching on the unit, check that the block and control valves are set correctly.

Startup / Shutdown When all conditions have been fulfilled, the driving motor can be switched on. Longer operation with closed or only minimally opened dischargeside valve can lead to strong heating of the pump.

Caution The pump may only be operated below the minimum operating range for a short period of time. The minimum flow rate is given in the characteristic curve. 4.1.4 Monitoring The unit should be monitored continuously during the first hours of operation. In this way it is possible to identify irregularities immediately and to take appropriate steps to eliminate them. Regular monitoring of the unit is of vital importance for safe operation with regards to explosion protection. Danger Check the safety equipment for damage, correct positioning and fastening at regular intervals. During operation of the unit there is a danger of injury inside the freely accessible areas from rotating parts.    



Check the unit for steady, vibration-free operation. Unusual noises are an indication of a fault. Check the oil supply. Check the temperature on the outside surface of the bearing. It should not exceed 85°C. For rotating mechanical seals: Check the leakage rate at the rotating mechanical seal. It may amount to at most 5 cm3/h. If the leakage rate is higher, the unit must be switched off immediately. Check the seal face and seal seat and replace if necessary (see supplier's documentation). For stuffing box packing: Check the stuffing box gland and adjust if necessary. A slight leakage rate is required.

Startup / Shutdown

Caution The plant must be shut down immediately if the sealing system or oil supply fails. 

Monitor the power consumption of the drive.

4.1.5 Precautionary Measures  

The flow rate should always be above the minimum in the operating range. This prevents overheating and high vibration. If possible, avoid sudden changes in temperature. Shaft sealing with a stuffing box or shaft sealing ring is only permitted with a suitable temperature control.

4.2

Shutdown Danger The shutdown procedures described below serve the safety of the operating and maintenance personnel. They must therefore be followed strictly.  

Close the block valve in the discharge line. Switch off the driving motor. Caution If the rotor stops suddenly, it must be feared that the rotor has collided with something. The pump must then be opened and all gaps checked.

 

Watch the rotation of the rotor until it comes to a stop. Take the above-mentioned steps if necessary. Close the block valve in the suction line. Danger There is a danger of injury if the unit is started or block valves opened unintentionally.

 

Secure the driver against unauthorized restarting. Secure the block valves against unauthorized opening.

Startup / Shutdown  

Close all block valves in the auxiliary pipes. Empty the pump and auxiliary pipes.

Caution All cooling chambers and cooling water lines must be drained at outside temperatures below 0°C.

4.3

Measures for Standstill The measures necessary depend on the duration of the planned standstill.

4.3.1 Short Standstill If the unit came to a stop faultlessly and without a jerk, it can be started again without any special measures being taken. If the unit was shut down because of a danger or fault, it must be checked for damage.

4.3.2 Longer Standstill 

Switch off the driver. Danger There is a danger of injury if the unit is started or block valves opened unintentionally.

    

Secure the driver against unauthorized restarting. Secure the block valves against unauthorized opening. Mask the vent filter on the bearing housing to reduce the air exchange. If the plant is operable, start the unit monthly and run it until it is warm (see chapter "Startup"). If the plant is not operable, turn the pump a few times by hand monthly.

Drain the pump and auxiliary pipes if there is a danger of frost. An oil change should be carried out before the pump is started again.

Maintenance

5

Maintenance 5.1

Notes on Maintenance Only carry out work for which you have the necessary qualifications, instruction and authorization from management! Take the necessary measures to protect against unauthorized switching on of the drive during maintenance work. Maintenance of the unit is important for safe operation with regards to explosion protection.

5.2

Maintenance Schedule Regular maintenance work is necessary to ensure troublefree operation of the unit. Danger Check the safety equipment for damage, correct positioning and fastening at regular intervals. During operation of the unit there is a danger of injury inside the freely accessible areas from rotating parts.

5.2.1 Inspections on Running Unit    





Check the unit for steady, vibration-free operation. Unusual noises are an indication of a fault. Check the oil supply. Check the temperature on the outside surface of the bearing. It should not exceed 85°C. For rotating mechanical seal: Check the leakage rate at the rotating mechanical seal. It may amount to at most 5 cm3/h. If the leakage rate is higher, the unit must be switched off immediately. Check the slide ring and counter ring and replace if necessary (see supplier's documentation). For stuffing box packing: Check the stuffing box gland and adjust if necessary. A slight leakage rate is required. Monitor the power consumption of the driver.

Maintenance 

Check all additional systems for working order (e.g. sealing system and cooler). Caution The plant must be shut down immediately if the sealing system or oil supply fails.

5.2.2 Inspections on Dismantled Pump After three years or 25,000 hours of operation it is advisable to dismantle and inspect the pump. The procedure is described in the instruction handbook for the pump. Carry out the following work:          

Inspect the casing for wear and tear. Clean and inspect all auxiliary pipes. Inspect the transmission elements of the coupling. Inspect all individual parts for damage. Inspect all impellers for wear and tear. Inspect the radial gaps for compliance with the values in the gap clearance table. Clean and inspect the bearings. Inspect the rotating mechanical seals and shaft sleeves for wear and tear. Replace all flat gaskets, sealing rings and O-seals. Inspect the pump shaft for radial run-out. The run-out may not exceed 0.03 mm at the fitting positions.

Damaged parts must be replaced. Please see the supplier's documentation for further information.

5.3

Lubricant Change The intervals specified are intended to serve as a guide only and may vary depending on the operating conditions.

Maintenance 5.3.1 Oil Change The first oil change must be carried out three weeks after initial startup, all further oil changes in intervals of six months or 4000 hours of operation, whichever occurs first. The machine must be switched off for an oil change. The discharging oil is hot and can lead to burns.

We recommend lubricating oils according to DIN 51519 for lubrication of the bearings. Carry out the oil change as follows: 

Switch off the driving motor.



Drain the oil and clean the bearing housing with a suitable washing liquid.



Remove the ventilation filter and fill in ¾ of the oil with a funnel.



Take off the tank of the constant-level oiler and fill with oil.



Place the tank back on the constant-level oiler.



Refill the tank as often as is necessary until it remains at least two-thirds full.

Maintenance 5.3.2 Grease Lubrication The regreasing interval is 4000 hours of operation. Excessive regreasing is just as harmful as deficient lubrication. Brief increases in temperature shortly after regreasing are normal. After a run-in period of eight hours, however, the bearing temperature, measured on the outside wall of the bearing housing, should not exceed 80°C. Every good brand-name lithium soap grease with soft consistency is suitable for grease lubrication.

Troubleshooting

6

Troubleshooting The table below provides an overview of possible faults and their possible causes. If faults that are not named here occur or the faults cannot be attributed to the causes named here, we recommend you contact the manufacturer.

Faults

Reference Numbers for Cause and Correction

Flow rate too low

1, 2, 3, 4, 5, 6, 7, 8, 9, 17, 18

Pump head too low

2, 3, 4, 5, 6, 7, 8, 9, 17, 18

Delivery pressure too high

9, 11

Power consumption of the pump too high

9, 10, 11, 13, 14, 17, 18, 21

Pump gets hot

2, 5, 22

Pump runs unsteadily

2, 3, 4, 5, 6, 8, 10, 13, 14, 20, 21, 22

High bearing temperature

13, 14, 15, 16, 21

Shaft seal leaks

12, 13, 16

Pump casing leaks

19

Troubleshooting 6.1

Causes and Corrective Measures

Ref. No.

Cause

Correction

1

The back pressure of the plant is higher than the design point of the pump.

Open the shut-off device on the discharge side until the operating point is reached.

2

The pump or pipes are not properly vented or filled.

Vent or fill.

3

Supply line or impeller blocked.

Clean pipes and impeller.

4

Air pocket in the pipe.

Fit vent valve. If necessary, use a different pipe routing.

5

NPSHUnit too low.

· Check level of liquid in the supply tank. · Open the shut-off device in the supply line completely. · Lay the supply line differently if the frictional losses are too high. · Check filter, if any, in the supply line.

6

Wrong direction of rotation of the Reverse the polarity of any two phases pump. at the motor.

7

Speed too low.

Increase speed. Consultation with the manufacturer necessary.

8

Internal pump parts worn.

Replace worn parts.

9

Density or viscosity of the Consultation with the manufacturer pumping medium different to the necessary. design data.

10

Pump head lower than the Set the operating point with the shutnominal pump head of the pump. off device in the discharge line.

11

Speed too high.

Reduce speed. Consultation with the manufacturer necessary.

12

Shaft seal is damaged.

Inspect shaft seal parts and replace if necessary.

13

Pump unit is not aligned correctly.

Realign pump.

14

Stressed pump.

Inspect the pipes for stress-free connections.

Troubleshooting 15

High axial thrust.

Clean balance opening in the impeller and replace sealing rings.

16

The coupling half gap is not set correctly as specified.

Readjust. See floor plan for gap size.

17

The motor voltage is not correct.

Use motor with the correct voltage.

18

Motor only runs on two phases.

· Check cable connection. · Replace fuse.

19

Screws have not been tightened enough.

· Tighten screws. · Replace seals.

20

Impeller unbalance.

Clean impeller. Re-balance impeller.

21

Bearing defective.

Replace bearing.

22

Flow rate below minimum flow rate value.

Increase flow rate to minimum flow rate value.